GD825A 2 Workshop

SEBM002308
GD825A- 2
MACHINE MODEL
SERIAL No.
GD825A-2
11001 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
GD825A-2 mount the S6D140-1 and S6D140E-2 engine.

For details of the engine, see the 6D140-1 and 6D140-2 Series Engine Shop Manual.
2011 1
All Rights Reserved
Printed in Japan 02-11(01)
00-1
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revision
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00-2-5
(8)
Safety notice
(Rev. 2008/08)1
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
welding work, alw ays wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
00- 3
(7)
2.
3.
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
Precautions during work
1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
00- 4
(7)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
4.
Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
00- 5
(7)
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.
00- 6
(7)
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00- 7
(7)
How to read the shop manual

q
q
q
1.
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
00- 8
(7)
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
5.
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00- 9
(7)
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Standard size and tolerance

q
To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size
Tolerance
0.022
0.126
120
a
The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
00- 10
(7)
Tolerance
Shaft
0.030
0.076
Hole
+0.046
+0
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
5.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4.
Repair limit and allowable value or allowable dimension

q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
6.
Clearance limit
q
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
00-
11
(7)
Handling of electric equipment and hydraulic component
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
00- 12
(7)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be shortcircuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing
electricity through it.
5)
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
00-
13
(7)
3.
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q
00- 14
(7)
When removing from clips

Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3]
Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
2)
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-
15
(7)
3)
00- 16
(7)
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
Disconnection
Connection (Example of
incomplete setting of (a))
4)
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
o i l an d w at e r f r o m t h e c om pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-
17
(7)
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
00- 18
(7)
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-
19
(7)
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
00- 20
(7)
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
00-
21
(7)
3.
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
107 engine
2)
00- 22
(7)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3)
While pressing lock (D), pull out connector

(4) in the direction of the arrow.
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-
23
(7)
How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Symbol
Low-voltage
wire for
automobile
AV
Thin-cover
low-voltage
wire for
automobile
AVS
Heat-resistant low-voltAEX
age wire for
automobile
00- 24
(7)
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
00-
25
(7)
3.
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
00- 26
(7)
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
D
6
8
10
12
14
16
18
20
22
24
27
07049-02734
27
Dimensions
d
L
5
8
6.5
11
8.5
12
10
15
11.5
18
13.5
20
15
22
17
25
18.5
28
20
30
22.5
34
00-
27
(7)
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
00- 28
(7)
4)
5)
Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
00-
29
(7)
Method of disassembling and connecting push-pull type coupler

k
k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
00- 30
(7)
Type 2
1.
2.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
00-
31
(7)
Type 3
1.
2.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00- 32
(7)
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
The following table applies to the bolts in Fig. B.

mm
6
8
10
12
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Width across flats

mm
10
12
14
17
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-
33
(7)
2.
Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm
10
12
16
3.
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No.
02
03,04
05,06
10,12
14
4.
Width across flats

mm
14
17
22
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84
132
{
8.5
13.5}
103
{10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
00- 34
(7)
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
00-
35
(7)
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
00- 36
(7)
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
Conversion table
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.
Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
00-
37
(7)
Millimeters to inches
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
0
10
20
30
40
0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
00- 38
(7)
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
7
50.6
123.0
195.3
267.6
340.0
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
8
9
57.9
65.1
130.2
137.4
202.5
209.8
274.9
282.1
347.2
354.4
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
00-
39
(7)
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
00- 40
(7)
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-
41
(7)
01
GENERAL
Specification
dimension drawings ...............
Specifications.. ................................................
Weight table ..................................................
Fuel, coolant and lubricants ........................
01-2
01-4
01-7
01-8
01-l
0
SPECIFICATION
GENERAL
SPECIFICATION
DIMENSION
DIMENSION
DRAWINGS
DRAWINGS
Unit: mm
Serial No.: 11001 - 12050
-I
c
c
0
-
SWG00332
01-2
0
GENERAL
SPECIFICATION
DIMENSION
DRAWINGS
Serial No.: 12051 and up
Unit: mm
c
c
a
P
01-3
0
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine
Serial
Overall
model
G D825A-2
No.
weight
11001 - 12000
12001-
12050
12051 and up
29,680
kg
29,680
29,680
Load on front wheel
kN {kg1
78.9 {8,040)
78.9 (8,040)
78.9 (8,040)
Load on rear wheel
kN (kg1
212.2 121,640)
212.2 (21,640)
212.2 (21,640)
Overall
length
mm
11,470
11,470
11,470
Overall
width
mm
3,310
3,310
3,310
Overall
height (to top of cab)
mm
3,550
3,550
3,550
Overall
height (to tip of muffler)
mm
2,605
2,605
2,605
mm
7,100
7,100
7,100
mm
1,840
1,840
1,840
(front)
mm
2,620
2,620
2,620
(rear)
mm
2,620
2,620
2,620
mm
440
440
440
1st
km/h
4.0
4.0
4.0
2nd
km/h
5.4
5.4
5.4
Wheelbase
Distance
between
tandem
Tread
Ground
clearance
Forward
Reverse
t
Drawbar
pull
Gradeability
Min. turning
Static stability
01-4
0
centers of
wheels
radius
3rd
km/h
8.0
8.0
8.0
4th
km/h
11.5
11.5
11.5
5th
km/h
15.8
15.8
15.8
6th
km/h
21.4
21.4
21.4
7th
km/h
31.3
31.3
31.3
8th
km/h
44.9
44.9
44.9
1st
km/h
4.3
4.3
4.3
2nd
km/h
5.8
5.8
5.8
3rd
km/h
8.5
8.5
8.5
4th
km/h
12.2
12.2
12.2
5th
km/h
16.9
16.9
16.9
6th
km/h
22.8
22.8
22.8
7th
km/h
33.4
33.4
33.4
8th
km/h
47.9
47.9
47.9
tN {kg)
169.85 {17,320)
169.85 {17,320}
169.85 (17,320)
deg
24
24
24
7.9
7.9
7.9
deg
35
35
35
GENERAL
SPECIFICATIONS
Machine
Serial
model
No.
Model
G D825A-2
4-cycle, water-cooled,
Type
vertical,
in-line,
direct injection
type,
ith turbocharger
No. of cylinders
- Bore x stroke
mm
6-140x165
6-140x165
6-140x
15.24 {I 5,240I
15.24 {I 5,240)
15.24 {I 5,240)
165
Piston displacement
.Q{cc1
Flywheel
:W/rprr
209/2,100
209/2,100
209/2,100
-iP/rpm
{280/2,100)
~280/2,1001
{280/2,100)
lm/rpn
1,255/l ,400
1,255/l ,400
1,255/l ,400
:gm/rprr
{128/1,4001
{I 28/l ,400)
{128/l ,400}
horsepower
Max. torque
Low idling
rpm
2,350
2,350
2,350
High idling
rpm
650
650
650
g/kWh
201
208
208
g/HPhl
{I501
11551
{I 551
Min. fuel consumption
Starting
ratio
24V, 11 kW
motor
24V, 50A
Alternator
12V, 160Ahx2
Battery
Planetary
gear type, power
multiple
Transmission
disc clutch,
actuated,
force
lubrication
feed,
deduction
gear
Spiral bevel
Tandem
U
3
_
z
5
2
q
ij
t
z
Fullv
device
Leaning
Max.
Elliott
Hydraulic
leaning
angle
deg
14.5
Type
I
Fully hydraulic
Steering
tandem
transmission
Reverse
Type
and planetary
angle
gear
reduction
floating,
Chain
pump
8 speeds,
8 speeds
gear
2-stage
3ear axle
gear
forward
reverse
shift type,
hydraulically
14.5
type
tvoe
type
angle
type
14.5
type (Orbit-roll)
deg
50
50
50
deg
25
25
25
ii
Max.
articulating
angle
01-5
0
GENERAL
SPECIFICATIONS
Machine
model
Serial
No.
Size
Inflation
G D825A-2
pressure
11001 - 12000
12001-
(front)
18.00-25-12PR
23.5-25-l
2PR
23.5-25-l
2PR
(rear)
18.00-25-i
23.5-25-l
2PR
23.5-25-l
2PR
(front,
rear
2PR
12050
12051 and up
kPa
240
240
240
:kg/cm?
(2.45)
(2.45)
{2.45}
Rear 4-wheel
Main brake
braking
Wet type, multiple
disc
Air actuated
Transmission
Parking
brake
Dry-type,
output
released
Dimensions
(length
(arc height)
Dimensions
x height
mm
x thickness)
of cutting
4,928
800
4,928
(695) x 25
edge
mm
shaft braking
disc type, spring actuated,

bv air
x
800
4,877
(695) x 25
a60
(750) x 25
2,438 x 203 x 19 i 1,438 x 203 x 19 i !,438 x 254 x 25

- 2 pieces
- 2 pieces
- 2 pieces
mm
490
420
450
mm
680
680
950
(left)
mm
1,920
1,920
1,920
Max. side shift distance (right
mm
2,070
2,070
2,070
Turning
angle
deg
360
360
360
Digging
angle
(max.)
deg
a4
a4
115
(min.)
deg
25
25
63
Max. lifting height

(from ground)
Max. lowering
depth
(from ground)
Max. side shift distance
Parallelogram
Type
Shank
Standard
to install 7)
149 {15,2001
149 {15,200)
Ripping width
mm
2,978
2,978
2,978
Max. lifting height
mm
675
615
615
mm
480
deg
42.3
of ripper
149 {15,2001
kN {kg1
Weight
3 (possible
type
(from ground)
Max.
lowering
depth
480
(from ground)
Ripping
01-6
0
angle
52
52
WEIGHT TABLE
GENERAL
WEIGHT TABLE
a
Thus
. weight
table
is for use when
handling
components
or when
transporting
the machine.
Unit:
Machine
Engine
assembly
Radiator
Final drive
Tandem
Front
(dry)
assembly
(dry)
assembly
drive
axle
(except
11001 - 12000
(dry)
assembly
Transmission
No.
(dry)
assembly
Fuel tank
GD825A-2
model
Serial
assembly
(each)
assembly
leaning
Front frame
Rear frame
cylinder
and steering
assembly
assembly
Operators
compartment
assembly
kg
12001-12050
12051 and up
1,360
1,360
1,360
183
183
183
298
298
298
1,147
1,147
1,147
1,802
1,802
1,802
1,242
1,242
1,242
1,024
1,024
1,085
2,982
2,982
2,982
2,093
2,093
2,093
300
300
300
1,000
1,040
1,040
1,125
1,090
1,090
1,160
1,160
1,320
1,540
1,540
1,600
278
278
300
530
530
530
83
83
83
26
26
26
cylinder)
(incl. control)
ROPS cab assembly
(OPT, High ROPS cab assembly)
Drawbar
assembly
Blade assembly
Circle rotation
assembly
Wheel assembly
Power tilt cylinder
Leaning
cylinder
assembly
assembly
Blade lift cylinder

Drawbar
assembly
shift cylinder
Blade shift cylinder

Steering
Articulate
cylinder
(dry)
Hydraulic
tank (dry)
Hydraulic
pump
Transmission
pump
Circle rotation
Ripper assembly
assembly
motor
158 x 2
160 x2
72
72
74
106
106
105
15 x2
cylinder
Ripper cylinder
assembly
158x2
15 x 2
15 x2
72
72
72
130
130
130
53
53
53
106
106
106
12
12
12
55
55
15
2,025
2,025
2,025
01-7
0
GENERAL
FUEL, COOLANT
FUEL, COOLANT
AND
LUBRICANTS
AND LUBRICANTS
Serial No.: 11001 - 12050
UND OF
FLUID
RESERVOIR
AMBIENT
-22
.30
-4
-20
14
-10
32
0
TEMPERATURE
50
10
68
20
CAPACITY
104
40
86
30
122F
50C
Specified
(J?)
Refill
34 (36)
Engine oil pan
+
Transmission
case
25
Engine
oil
Final drive case
63
Tandem case (each)
57
95
Front axle housing

Hydraulic
system
80
Circle rotation
(Brake case)
gear case
Circle rotation
(Gear case)
gear case
Fuel tank
Cooling
system
0.18
Gear
oil
16
Diesel
fuel
500
Coolant
Add antifreeze
z ASTM
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic maintenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Fuel sulphur
content
Change interval of oil in

engine oil pan
0.5 to 1.0%
l/2 of regular
interval
Above
l/4 of regular
interval
ASTM:
SAE:
API:
1.0%
j8 (78.5)
D975 No.1
1: Serial No. 12001 - 12050
(2) When starting the engine in an atmospheric

temperature
of lower than OC, be sure to
use engine oil of SAEIOW, SAEIOW-30
and
SAE15W-40,
even though an atmospheric
temperature
goes up to 10C more or less in
the day time.
(3) Use API classification CD as engine oil and if
API classification
CC, reduce the engine oil
change interval to half.
American Society of Testing and Material

Society of Automotive
Engineers
American Petroleum Institute
Specified capacity: Total amount of oil including oil for components

Refill capacity: Amount of oil needed to refill system during normal
01-8
0
and oil in piping.

inspection and maintenance.
GENERAL
Serial
FUEL, COOLANT
AND
No.: 12051 and up
<IND OF
FLUID
RESERVOIR
AMBIENT
-22
-4
14
TEMPERATURE
32
50
68
86
CAPACITY
104
122F
Transmission
Refill
40
36
35
25
case
Engine
oil
Final drive case
63
Tandem case (each)
120
Front axle housing
0.9
Hydraulic
140
system
+
Circle rotation
Brake case
gear cast
Cooling
Gear
oil
system
Coolant
Add antifreeze
s ASTM
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic maintenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Fuel sulphur
content
Change interval of oil in

engine oil pan
57
95
L
80
+
10
Diesel
fuel
Fuel tank
(k?)
Specifiec
Engine oil pan
ASTM:
SAE:
API:
LUBRICANTS
500
t
78.5
D975 No.1
(2) When starting the engine in an atmospheric

temperature
of lower than OX, be sure to
use engine oil of SAEIOW, SAEIOW-30
and
SAE15W-40,
even though an atmospheric
temperature
goes up to 10C more or less in
the day time.
(3) Use API classification CD as engine oil and if
API classification
CC, reduce the engine oil
change interval to half.
American Society of Testing and Material

Society of Automotive
Engineers
American Petroleum Institute
Specified capacity: Total amount of oil including oil for components

Refill capacity: Amount of oil needed to refill system during normal
and oil in piping.

inspection and maintenance.
10
STRUCTURE AND FUNCTION
General ..........................................................
IO- 2
Power train diagram ....................................
IO- 3
Joint ...............................................................
IO- 4
HYDROSHIFT transmission
and transfer
piping ......................................................
IO- 5
Hydraulic circuit for power train ................ IO- 6
Hydraulic circuit diagram for
power train .............................................
IO- 7
PTO (Power Take Off) ..................................
IO- 8
and
transfer ....................................................
IO-I 0
Transmission
control valve .........................
IO-16
Transmission
control ...................................
1O-30
inching control .............................................
IO-32
Drive shaft ....................................................
.
1o-33
Final drive, differential lock and
unlock piping.. ........................................
IO-34
Final drive .....................................................
1O-36
Tandem drive ...............................................
1o-39
Steering piping .............................................
IO-41
Steering circuit system ................................
IO-42
Steering circuit diagram.. ............................
1o-43
Steering valve.. .............................................
IO-44
Double relief valve .......................................
1O-48
Check valve.. .................................................
IO-49
Emergency steering system ........................
IO-50
Front axle ......................................................
IO-51
Wheel ............................................................
1O-52
Disc brake .....................................................
IO-53
Parking brake.. ..............................................
1o-55
Brake air piping ............................................
1 O-56
Brake air circuit system ...............................
1O-58
Brake air circuit diagram .............................
1o-59
Air drier .........................................................
1O-60
Air governor .................................................
1 O-62
Air tank ..........................................................
1 O-64
Safety valve ..................................................
1O-64
Automatic drain valve ...............................
IO- 65
Check valve.. ...............................................
IO- 67
Brake valve .................................................
IO- 68
Parking brake system ................................

IO- 72
Parking brake solenoid valve.. .................. IO- 72
Exhaust valve .............................................
IO- 74
Spring cylinder ...........................................
IO- 75
Hydraulic control piping ............................
IO- 76
Hydraulic circuit system ............................
IO- 80
Hydraulic circuit diagram ........................
10-80-2
Closed center load sensing system
(CLSS) ..................................................
10-81-I
Hydraulic pump.. ........................................
IO- 82
Priority flow divider valve .........................
IO- 87
Surge pressure absorbing valve .............. IO- 93
Hydraulic control valve.. ............................
IO- 96
Pressure compensating
mechanism
of hydraulic control valve ................... IO- 98
Blade lift speed adjustment
mechanism ........................................
10-100-4
Pilot check valve .........................................
IO-102
Pilot check valve (with safety valve). ..... ..lO-10 4
Circle rotation motor .................................
IO-106
Blade accumulator
system ........................
IO-109
Blade float system .....................................
IO-I 11
Drawbar and lifter ......................................
IO-I 12
Blade .........................................................
1 O-l 13-3
Lifter bracket control piping.. .................... IO-I 14
Circle rotation gear ....................................
IO-I 15
Rear mount ripper ......................................
IO-I 17
Hydraulic control linkage ..........................
IO-I 18
Main frame .................................................
IO-120
Air conditioner .........................................
10-120-1
Electrical wiring diagram ..........................
IO-121
Monitor panel, cluster gauge and
pilot lamp .............................................
IO-125
Electrical circuit diagram ...........................
IO-128
Electronic vehicle monitoring system
(EVMS) ..................................................
IO-147
Transmission
control system .................... IO-153
Sensors .......................................................
IO-156
Engine starting circuit ................................
IO-162
Engine stopping circuit ..............................
IO-168
10-l
0
GENERAL
El
F23507003
The power produced by diesel engine (I) goes to HYDROSHIFT transmission (3) through joint (2).
Transmission (31, with a planetary gear mechanism
and a hydraulic control unit combined, allows an easy
selection of eight forward speeds and eight reverse
speeds. Through drive shaft (41, the power is transmitted from the transmission
to the final drive (5).
Here, final drive (5) directs the power to the right and
left, and the power is transmitted to the left and right
tandem drives (6).
Tandem drive (6) transmits the power to the wheel
by a chain and the machine travels.
1o-2
1.
2.
3.
4.
5.
6.
Engine
Joint
Drive shaft
Final drive
Tandem drive
POWER
TRAIN
DIAGRAM
F23501004
1. Engine
2. Joint
3. PTO (Power
Take Off)
4. HYDROSHIFT
transmission
5. Transfer
6. Parking
brake
7. Drive shaft
8. Final drive
9. Tandem
drive
10. Tire
P,
Hydraulic
P,
Transmission
pump
P,
Differential
pump
lock pump
1o-3
0
JOINT
Engine
-..
T
---2
13
F23501007
1o-4
1.
Engine flywheel
2.
Plate
3.
Tube
4.
PTO input
shaft
r-n
c----q
_-_--_$
- - _.-
YI
r-.
- __i--i_~.-=&
/l-
- - *_-,-y_
1. Transfer
2.
HYDROSHIFT
3.
Transmission
control
4.
Transmission
filter
pump
5.
Transmission
6.
Engine
7.
Radiator
8.
Oil cooler
The
oil
mission
.
valve
in transmission
pump
The oil from

mission
235CD02001
transmission
filter
(5) through
transmission
by
trans-
the strainer.
pump
(5) flows
(4), and transmission
(3).
Then the oil flows
be cooled
(2) is sucked
to oil cooler
to trans-
control
(8) in radiator
and to the transmission
to lubricate
valve
(7) to
it.
1o-5
HYDRAULIC
CIRCUIT FOR POWER TRAIN
Engine running, gear shift lever in NEUTRAL

Serial No.: 11001 - 12012, 12016 - 12018
R
4th
3rd
2nd
1st
235FO2001
1O-6
0
STRUCTURE
AND
HYDRAULIC
Serial
FUNCTION
HYDRAULIC
CIRCUIT DIAGRAM
No.: 11001 - 12012,
CIRCUIT
DIAGRAM
FOR POWER TRAIN
FOR POWER TRAIN
12016 - 12018
0. 29-3 04HPa
13-3lks/cm'l
t----t------6
4th
1. OGMPa
3rd
(10. Bka/cm'i
II
I
!________
i
)I(
LL
0 29HPa
_
1.
2.
3.
4.
5.
6.
7.
8.
Transmission
case
Strainer
Transmission
pump
Transmission
filter
Priority valve
Modulating valve
Quick return valve
Pilot oil filter
,;!
9. Pilot reducing
10. Transmission
11.
12.
13.
14.
15.
16.
valve
lubrication
Oil cooler
Transmission
lubrication
Oil cooler bypass valve
Inching valve
F-R clutch spool
4th clutch spool
relief valve
17.
18.
19.
20.
21.
22.
23.
3rd clutch spool

2nd clutch spool
1st clutch spool
High clutch spool
Low clutch spool
Emergency spool
Solenoid valve
1o-7
0
STRUCTURE
AND
HYDRAULIC
FUNCTION
HYDRAULIC
CIRCUIT
FOR POWER TRAIN
CIRCUIT FOR POWER TRAIN
Engine running, gear shift lever in NEUTRAL

Serial No.: 12013 - 12015, 12019 and up
SWG00336
1o-7- 1
0
STRUCTURE
AND
HYDRAULIC
Serial
HYDRAULIC
FUNCTION
CIRCUIT DIAGRAM
No.: 12013 - 12015,
CIRCUIT
DIAGRAM
FOR POWER TRAIN
FOR POWER TRAIN
12019 and up
0.29-3.04HPa
13-3lka/cm'l
1 47HPa
il5ks/cm'l
&
5
L--J
t--j
I.OGMPa
(IO Bkefcm'l
-___p~-~-~-----------__
9
I--_-dI II
)I(
LL
0 49MPa
15ks/cm'l
SWG00335
1. Transmission
2.
3.
4.
5.
6.
7.
8.
case
Strainer
Transmission
pump
Transmission
filter
Priority valve
Modulating valve
Quick return valve
Pilot oil filter
9. Pilot reducing valve

10. Transmission
lubrication
11. Oil cooler
12. Transmission
lubrication
13. Oil cooler bypass valve
14. Inching valve
15. F-R clutch spool
16. 4th clutch spool
relief valve
17.
18.
19.
20.
21.
22.
23.
3rd clutch spool

2nd clutch spool
1st clutch spool
High clutch spool
Low clutch spool
Emergency spool
Solenoid valve
10-7-2
0
PTO (Power
Take Off)
2
B-B
235FO2003
1,
A-A
1 O-8
F2350
1008-2
1.
Input shaft
2.
Idler gear
3.
Pump drive
4.
Transmission
gear
pump
5.
Transmission
control
valve
STRUCTURE
AND
FUNCTION
HYDROSHIFT
HYDROSHIFT
TRANSMISSION
TRANSMISSION
AND TRANSFER
AND TRANSFER
Serial No.: 11001 - 12012,12016 - 112018
B-B
A-A
c-c
235FO2004
2
l
The oil in the transmission

mission
pump
through
is sucked
strainer
The oil from
the transmission
transmission
filter,
(2).
10-10
0
by the trans-
(3).
pump
and transmission
1.
Breather
2.
Transmission
flows
to the
3.
Strainer
control
valve
4.
Drain plug
control
valve
HYDROSHIFT TRANSMISSION AND TRANSFER
023502
10-12
(6)
HYDROSHIFT TRANSMISSION AND TRANSFER
023502
10-14
(6)
TRANSMISSION
CONTROL VALVE
Serial No.:11001 - 12012,12016-12018
235coo2039
1.
Connector
A.
Inching
2.
Lower
valve
B.
Main pressure
3.
Upper
valve
C.
Priority
D.
Oil cooler
E.
Lubricating
10-16
0
pressure
pick-up
pick-up
pressure
bypass
pick-up
pressure
pressure
pick-up
pick-up
UPPER VALVE
-iid
r-71
1.
Housing
2.
Inching
3. . huick
valve
return
4.
Modulating
5.
Priority
6.
Oil cooler
valve
valve
valve
bypass
235CDO2040
\
4
1
valve
Y-Y
OUTLINE
l
The oil from
the transmission
pump
enters
and
through
valve
(5). It is then
passes
divided
into
two
and the other

valve
valve
The
oil flowing
trols
the pilot
tional
lines:
to pilot
one to the clutch

reducing
(5) acts to control
reducing
l
priority
reducing
valve
the two
(12) is the priority

to pilot
pressure
and speed
each spool
valve
spools.
port A,
pistons,
(12). Priority
lines so that
pilot
valve
(12) con-
used to actuate
the direc-
The oil regulated

through
The
by pilot
the orifice
other
return
ing valve
(4) and quick
clutch
pressure
when
actuating
3rd,
change
.
oil line flows
and quick
2nd,
circuit.
reducing
(12) presses
4th,
valve
to
modulating
(3). The action

return
smoothly.
valve
valve
(3) raises the
This reduces
the shock
the FORWARD,
REVERSE
High
speed
and
Low
(4)
of modulat-
and Ist,
clutches
to
gear.
Lubrication
valve
(14) controls
the
lubrication
oil
inside the transmission.
in
and fills the spool.
10-17
LOWER VALVE
235CD02041
7. High clutch
spool
8. 2nd spool
9. Low clutch
spool
10. 4th spool

11. 1st spool
12. Pilot reducing
valve
13. F-R spool

14. Lubrication
15. 3rd wool
lo-18
valve
SOLENOID
VALVE
I I
11
Section X-X
10
F23501302
STRUCTURE
l
The
1. Valve
transmission
the transmission
control
valve.
together
When
ed, the solenoid

spool
solenoid
valve
with
is actuated
inside the transmission
to
the transmission
the gear shift
valve
is installed
valve.
body
2. 2nd solenoid
valve
3. 4th solenoid
valve
lever is operat-
4. 1 st solenoid
valve
and moves
5. L solenoid
valve
6. H solenoid
valve
the
7. 3rd solenoid
valve
8. F solenoid
valve
9. R solenoid
valve
10. Emergency
manual
spool
1 1. Connector
10-19
PRIORITY VALVE
Function
.
Priority
valve
ure required
oil to pilot
any other
(1) ensures
the minimum
for pilot reducing

reducing
valve
valve
oil press-
(2) and sends
(2) with
priority
over
circuit.
Operation
l
To each transmission spool
To modulating valve
When
the oil pressure
cm2), the
oil from
is below
pump
flows
priority
valve
and also into port
ducing
valve.
Since
lower,
the priority
the flow
to ports
sult, the oil from

pilot reducing
1.47 MPa (15 kg/

to port
the oil pressure
valve
moves
on port
valve
reA is
to the left, causing
A and C to be shut
the pump
A on the
B on the pilot
off. As a re-
is delivered
only to the
circuit.
423FO33
When
the oil pressure
kg/cm2),
pet
the hydraulic
spring
priority
valve
(3) push
is more
than
pressure
back
spring
(1) to the right.
port C to the clutch
spool.
(4) and
When
port A and port C are connected,

from
1.47 MPa (15
and force
To modulating valve
of popmove
this happens,
and the oil flows
Pi lot
oil filter
423FO34
1O-20
PILOT REDUCING VALVE
Function
l
The pilot
reducing
ure needed
valve
to actuate
acts to control
the press-
the transmission
spools.
Operation
l
The oil from
the pump
ter and enters
port
The oil passes through

the orifice
passes through
A of pilot
port
of transmission
the pilot fil-
reducing
valve
B and enters
spool
(1).
through
(2) to fill the in-
side of port C.
valve
423 FO30
When
the
urized
oil flows
valve
urized
from
inside
port
orifice
C rises,
of pilot
press-
reducing
(1) and goes to port D.
As a result,
right,
pressure
pilot
reducing
valve
(I) moves
to the
and ports A and B are shut off, so the pressoil
at port
C is maintained
at the
same
pressure.
423FO29
10-21
Function
of pilot circuit
This pilot valve

pressure:
drain
possible
port
at
drain
pressure
generated
pressure
as the primary
high as the primary

valve
secondary
the specified
at the Neutral
pressure
valve
secondary
If the reducing
a at the
to obtain
For example,
ondary
as a reducing
1.47 MPa (15 kg/cm*);
1.06 MPa (10.8 kg/cm2).

have
drain
functions
reducing
position,
port
pressure.
valve
does not
side,
it is im-
pressure.
if there
is no sec-
a, theoretically
at the secondary
side because
primary
pressure:
the
side is the same
(Actually,
of leakage
it is not as
from
the
spool.)
F23501306
1o-22
MODULATING
VALVE
AND
QUICK
RETURN
VALVE
Function
l
The modulating
together
to raise the transmission
smoothly.
In this
when shifting
eration
same
way.
operator
time,
they
reduce
the
in the power
fatigue
operator
is reduced,
comfort
clutch pressure
speed range, and prevent
of peak torque
result,
(kg/cm)
valve and quick return valve act
Shifting
gear
shock
the gen-
train. As a
and
at the
and the durability
of the power train are increased.
(Set)
Time
423FO35
11
Immediately
after
shifting
gear (Point A on Fig. 423FO35)
erection and speed spool
To pilot reducing
F23501303
Operation
l
The
oil sent from
valve
(I)
modulating
return
a
the pump
through
valve
valve
of quick
flows
A,
return
in pressure
between
port B and port
C. The quick return valve moves to the right and

the oil flows to clutch (5). In addition,
orifice
return valve
(3) and flows
to the
is opened,
has been actuated.
it passes through
difference
priority
through
through
oil passes
valve
from
passes
port B of quick
(21, and enters
(3). The
clutch pistion, which

er when
port
orifice
when quick
to the right, drain port D
and the pressurized
oil at the rear of
piston (4) flows to the drain circuit.
Howev-
a it creates
(3) moves
1 O-23
2)
Clutch
pressure
rising
(Point
B on Fig. 423FO35)
Direction
and Speed SpOOl
pilot
reducing
Ive
To oil cooler
F23501304
Operation
l
As the
pressure
pressure
at the clutch
piston
at port C also rises. Quick
(3) is pushed
rises, the
return valve
back to the left and drain port D is
closed. The oil from the pump flows from

to the
flows
clutch
piston,
and
at the
from orifice b through
same
port C
time
it
quick return valve
(3) and enters port E.

The oil at port E acts on the modulating
piston
(4). It pushes
piston
(4) to the rig ht.
1 O-24
back spring
(61 and moves
At
the
same
time,
the
orifice
through
modulating
valve
(2).
pressurized
and
enters
oil also passes

poppet
It moves modulating
(7)
of
valve
(2) to the left and some of the oil at port A flows

to port G.
3)
Completion
of rise in clutch
pressure
(Point C on Fig. 423FO35)
Direction and speed spool
pilot reducing
Ive
To
oil cooler
To inching valve
235FO2005
Operation
l
The oil entering

(4). When
port
the piston
the rise in pressure

pressure
reaches
to push
stops. When
this happens,
the set pressure
In addition,
(4), so the oil at port A passes
through
connected
the
of the modulat-
ing valve.
The oil at port
piston
the end of its stroke,
by piston
port G and flows

l
E continues
reaches
port F and port G are closed

through
to the oil cooler.
E is connected
the throttle
to the inching
(the modulating
with the inching
valve
valve
is inter-
valve).
1 o-25
OIL
COOLER
BYPASS
VALVE
FUNCTION
l
The
oil cooler
pressure
stant
bypass
valve
of the oil entering
pressure.
the specified
It drains
acts to maintain
the oil cooler
the
the
To each transmission
spool
at a con-
oil if it goes
above
pressure.
OPERATION
l
The
oil from
valve
(I)
the
and
then enters
pump
passes
actuates
through
modulating
port A and flows
priority
valve
(2). It
-2
to the oil cooler.
-1
To transmission
lubrication
From pump
F7.3501307
If the
oil
at
pressure,
it
port
passes
cooler
bypass
moves
oil cooler
result,
the oil from
flowing
specified
to
the
valve
A goes
port
the
orifice
(3) and enters
bypass
oil
above
through
valve
port
of
spool
oil
B. It then
(3) to the left. As a
A is drained,
cooler
specified
a
and the oil
is maintained
at the
pressure.
To transmission
lubrication
From pump
F23501308
1 O-26
TRANSMISSION
Function
.
There
SOLENOID
is one
directional
solenoid
and speed
VALVE
valve
spool
installed
for
each
in the transmission
valve.
When
the gear shift lever in the operators
partment
is
actuated,
operated,
the
and oil is drained
solenoid
to actuate
com-
valve
is
the direc-
tional and speed spools.
Operation
1)
Solenoid
valve OFF
The oil of spool (1) enters port A. However,

(2)
shuts
spool (I
off
the
oil, so directional
and
valve
speed
) does not move.
423FO31
4
8
2)
Solenoid
When
valve ON
the gear shift lever is operated,
the sole-
noid valve is pulled up.

The
enters
oil from
directional
port A and flows
circuit. Therefore,
sure circuit,
is moved
and
from
speed
port A becomes
and directional
spool
(I)
port B to the drain

the low pres-
and speed
to the right. As a result,
spool
(1)
the oil from
quick return valve flows to the piston.

Fr
reducing
valve
423 F032
1 O-27
Function
l
If there is any failure in the electrical

transmission
valve
control
does
not
system,
work,
used. This spool
the
circuit of the
and the
is attached
valve
the machine
*
mechanically.
attention
is
the trans-
(It is used to drive
to a place where
Particular
spool
to each directional
and speed spool and is used to operate

mission
solenoid
emergency
it can be repaired.)
must
be paid for when
using this spool.

Operation
1.
When
solenoid
(Emergency
When
valve
the solenoid
position)
valve is working
spool is maintained
Oil from
is normal:
spool is at normal
normally,
the
in this position.
directional
and speed
spool
(I)
enters
port A, but it is shut off by solenoid valve (2).
From.
~
reducing valve
2.
When
a.
solenoid
Clutch
valve
is abnormal:
in disengaged
(Emergency
manual
left (at normal

Emergency
position
spool is pushed
(3) is pushed
to the left,
and the oil at port A is shut off regardless
of
the
oil
action
cannot
of
flow
From quick
return valve
to the
position))
spool
423 F044
solenoid
valve
(2).
The
to port B, so the clutch
is not
actuated.
reducing valve
423 F045
b.
Clutch
in engaged
(Emergency
spool
actual
position))
When
emergency
right,
position
is pulled
spool
to the right
From quick
return valve
(3) is pulled to the
the oil at port A is drained
regardless
(at
of the operation
to port B
of solenoid
valve
(2). As a result, the clutch is actuated.
From
reducing valve
1 O-28
423 F046
INCHING
VALVE (INCHING
An inching
reduce
valve
with
the shock
VALVE WITH MODULATING
modulation
when
is employed
the inching
pedal
VALVE)
to
is oper-
From
ated.
OPERATION
1.
When
The
inching
valve
oil from
the
is not depressed;
pump
and B, goes through
passes
through
the F-R spool
ports
and is sent to
the F-R clutch.

The
return
valve
spring
spool
of the
(2) and collar
to the right.
The oil passing
ters chamber
prevents
valve
shut
orifice
(1)
Modulating
valve
D en-
to push valve
the tension
of the return
moving.
E of the
off by spool
To quick return
pushes
force
(1) from
The oil in chamber
pedal
push valve
through
C, and produces
(I) to the left. However,

spring
inching
(3). These
modulating
(2), so it does
valve
not flow
is
From pump
To oil cooler
bypass valve
to drain
port F.
2.
When
inching
When
the
valve
spool
valve
it
words,
clutch
of
the
between
modulating
to port
tension
drain
valve
and the
is reduced,
F and
(7) is opened
is drained.
hole
B is throttled
In addition,
port
E passes
Modulating
G, and the
so
inching
Valve
spool
valve
is fully
(2) moves
pas-
chamber
through
E of
(2), so
Modulating
valve
the throttle
(7) moves
pressure
is kept
to
re-
completely
to the
of spring
(5) is further
result,
hydraulic
pressure
the
the clutch
49 kPa (0:4 -
is completely
so
As a
zin
5 From pump
F-R clutch
0.5 kg/cm2),
and
disengaged.
The oil at port
E of modulating
nected
circuit
to drain
left,
reduced.
of the
From pump
235FO2007
depressed;
the tension
to 39 kPa -
To oil cooler
bypass valve
When
drops
1 n_:_ 4
Inch
duced.
3.
5A,
the
the
by spool
valve
main
of
in chamIn other
engaged.
the oil in chamber

drain
the
pressure.
F-R clutch
is partially
4 F
(I) to the left to a
with
the F-R clutch
the passage
pressure
and
valve
balances
From pump
Drain
depressed,
(5) and (6), and the oil pressure
ber C becomes
sage
depressed;
is slightly
to the left, so the oil press-
C pushes
where
springs
pedal
(2) moves
ure in chamber
position
is slightly
inching
valve
F, so the main
(7) is conpressure
is
kept reduced.
4.
Inching
valve
If spool
port
(closed
(2) closes
E continues
-r open)
drain
rises and returns
When
this happens,
is engaged
F, the oil entering
modulating
and the pressure
circuit
F-R clutch
circuit
to push
valve
(7) to
Modulating
valve
in the main
to the set pressure.
modulation
smoothly.
is applied,
so the
To oil cooler
bypass valve
From pump
235FO2008
1 O-29
TRANSMISSION
Serial No.: 12013 - 12015,
CONTROL VALVE
12019 and up
SWG00338
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
2nd connector
4th connector
1st connector
L connector
H connector
3rd connector
F connector
R connector
Lower valve
Upper valve
10-29-l
0
A.
B.
C.
D.
E.
Inching pressure pick-up

Main pressure pick-up
Priority pressure pick-up
Lubricating pressure pick-up
Oil cooler bypass pressure pick-up
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
LOWER VALVE
z-z
7.
8.
9.
10.
11.
12.
13.
14.
15.
High clutch spool

2nd spool
Low clutch spool
4th spool
1st spool
Pilot reducing valve
F-R spool
Lubrication valve
3rd spool
1O-29-3
SWG00339
SOLENOID
II
TRANSMISSION
CONTROL VALVE
VALVE
12
13
I4
15
Ifi
17
18
A-A
STRUCTURE
.
The transmission
solenoid
valve is installed
to the transmission
together
with the transmission
control
valve. When the gear shift
lever is operated,
the solenoid
valve is actuated and moves the spool inside transmission valve.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
12.
13.
14.
15.
16.
17.
18.
Valve body
2nd solenoid
valve
4th solenoid
valve
1st solenoid
valve
L solenoid
valve
H solenoid
valve
3rd solenoid
valve
F solenoid
valve
R solenoid
valve
Emergency
manual
2nd connector
4th connector
1st connector
L connector
H connector
3rd connector
F connector
R connector
SWG00340
spool
10-29-4
0
STRUCTURE AND
TRANSMISSION
FUNCTION
CONTROL
VALVE
PRIORITY VALVE
Function
.
Priority
valve
ure required
oil to pilot
any other
(1) ensures
the minimum
for pilot reducing

reducing
valve
valve
oil press-
(2) and sends
(2) with
priority
over
circuit.
Operation
l
To modulating valve
When
the oil pressure
cm),
the
oil from
is below
pump
flows
priority
valve
and also into port
ducing
valve.
Since
lower,
the priority
the flow
to ports
sult, the oil from

pilot reducing
to port
moves
A on the
B on the pilot
the oil pressure
valve
1.47 MPa (15 kg/
on port
reA is
to the left, causing
A and C to be shut off. As a rethe pump
valve
is delivered
only to the
oil filter
circuit.
423FO33
When
the oil pressure
kg/cm),
pet
the hydraulic
spring
priority
valve
(3) push
is more
than
pressure
back
spring
(1) to the right.
port C to the clutch
(4) and
When
port A and port C are connected,

from
1.47 MPa (15
and force
To modulating valve
of popmove
this happens,
and the oil flows
spool.
Pilot
oil filter
423FO34
1 O-29-5
0
PILOT REDUCING
TRANSMISSION
CONTROL VALVE
VALVE
Function
.
The pilot reducing
pressure
spools.
valve acts to control the

needed to actuate the transmission
Operation
.
The oil from the pump
passes through the

pilot filter and enters port A of pilot reducing valve (I). The oil passes through port B
and enters through the orifice of transmission spool (2) to fill the inside of port C.
To Priority
valve
SWG00421
When the pressure inside port C rises, pressurized oil flows from orifice a of pilot
reducing valve (I) and goes to port D.
As a result, pilot reducing valve (I) moves
to the right, and ports A and B are shut off,
so the pressurized oil at port C is maintained
at the same pressure.
The pressure at this point is 1.06 MPa (IO.8
kg/cm2).
To Priority
valve
SWG00422
10-29-6
0
STRUCTURE
AND
FUNCTION
Function of pilot circuit drain

This pilot valve functions
as a reducing
valve
primary pressure: 1.47 MPa {I5 kg/cm*}; secondary pressure:
1.06 MPa I10.8 kg/cm*}. If the reducing valve does not have drain port a at the
secondary
side, it is impossible
to obtain the
specified
reducing
pressure.
For example,
at the Neutral position,
if there is
no secondary
pressure at drain port a, theoretically the pressure
generated
at the secondary
side is the same pressure
as the primary
pressure. (Actually,
it is not as high as the primary
side because of leakage from the valve spool.)
1 O-29-7
0
TRANSMISSION
CONTROL
VALVE
STRUCTURE
AND
MODULATING
VALVE
Function
.
The modulating
together
result,
same
AND
valve
In this
shifting
eration
TRANSMISSION
QUICK
and quick
speed
of peak
operator
time,
way,
range,
torque
valve
clutch
reduce
the
power
is reduced,
comfort
and
act
(kg/cm*)
Shlftlng
40 -
the gen-
and
VALVE
gear
shock
train.
the
CONTROL
VALVE
pressure
and prevent
in the
fatigue
operator
of the power
they
RETURN
return
to raise the transmission
smoothly.
when
FUNCTION
As a
at the
durability
F
5
Z
k
30 -
20-
.=
0
train are increased.
Trne
1)
Immediately
after
shifting
(Set)
423FO35
gear (Point A on Fig. 423FO35)
F23501303
Operation
l
The
oil sent
from
valve
(1)
through
modulating
return
a
valve
valve
of quick
clutch
er when
pistion,
the
flows
A,
(21, and enters
(3). The
return
which
it passes
pump
port
oil passes
valve
from
passes
port
flows
has been actuated.
through
orifice
difference
the oil flows
orifice
return
to the
is opened,
Howev-
it creates
in pressure
C. The quick
B of quick
through
(3) and
priority
through
piston
valve
return
to clutch
(3) moves
and the
(4) flows
between
valve
port
moves
(5). In addition,
to the right,
pressurized
B and
to the right
when
drain
port
and
quick
port
oil at the rear of
to the drain circuit.
10-29-8
0
STRUCTURE
2)
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
Clutch pressure rising (Point Bon Fig. 423FO35)
Dir&m
and speed spool
pilot reducing
lve
F23501304
Operation
l
As the pressure
pressure
at the
at port
(3) is pushed
back
closed.
The oil from
to
clutch
the
flows
from
The
oil at port
(4). It pushes
(4) to the right.
1 O-29-9
0
piston
rises,
return
to the left and drain

the pump
piston,
orifice
(3) and enters
clutch
C also rises. Quick
and
flows
at the
through
quick
port
from
same
return
the
valve
D is
port C
time
E acts on the modulating

back
spring
(61 and moves
it
valve
port E.
piston
piston
At
the
same
time,
the
orifice
through
modulating
valve
pressurized
and
(2). It moves
(2) to the left and some

to port G.
enters
oil also
poppet
modulating
passes
(7)
of
valve
of the oil at port A flows
STRUCTURE
3) Completion
AND
FUNCTION
of rise in clutch pressure
TRANSMISSION
CONTROL
VALVE
(Point C on Fig. 423FO35)
irection
and speed
spool
It reducing
To inching
valve
235FO2005
Operation
The oil entering port E continues to push
piston (4). When the piston reaches the end
of its stroke, the rise in pressure stops. When
this happens, the pressure reaches 3.04 MPa
I31 kg/cm) as a set pressure of the modulating valve. In addition, port F and port G are
closed by piston (4), so the oil at port A
passes through port G and flows to the oil
cooler.
The oil at port E is connected to the inching
valve through the throttle (the modulating
valve is interconnected
with the inching
valve).
10-29-10
0
STRUCTURE
OIL
AND
FUNCTION
BYPASS
COOLER
TRANSMISSION
CONTROL
VALVE
VALVE
FUNCTION
l
The oil cooler

pressure
stant
bypass
valve
of the oil entering
pressure.
the specified
It drains
acts to maintain
the oil cooler
the
the
at a con-
oil if it goes
spool
above
pressure.
OPERATION
l
The
valve
oil from
the
(1) and
pump
passes
actuates
port A and flows
then enters
through
modulating
priority
valve
(2). It
to the oil cooler.
To transmission
lubrication
From pump
2
F23501307
%
z
If the
oil
at
pressure,
it
port
passes
cooler
bypass
moves
oil cooler
result,
the oil from
flowing
specified
to
the
valve
A goes above
through
(3) and enters
bypass
oil
pressure
port
the
orifice
valve
of
spool
oil
B. It then
port
(3) to the left. As a
A is drained,
cooler
specified
a
and the oil
is maintained
at the
of 0.49 MPa I5 kg/cm21.
To transmission
lubrication
From pump
F23501308
10-29-11
0
TRANSMISSION
SOLENOID
VALVE
Function
l
From quick
return valve
There is one solenoid valve installed for each

directional and speed spool in the transmission valve.
When the gear shift lever in the operators
compartment
is operated, the solenoid valve
is actuated, and oil is drained to actuate the
directional and speed spools.
Operation
I) Solenoid valve OFF
The oil of spool (I) enters port A. However,
valve (2) shuts off the oil, so directional and
speed spool (I) does not move.
2)
Solenoid valve ON
When the gear shift lever is operated, the
solenoid valve is pulled up.
The oil from directional and speed spool (I)
enters port A and flows from port B to the
drain circuit. Therefore, port A becomes the
low pressure circuit, and directional
and
speed spool (I) is moved to the right.
As a result, the oil from quick return valve
flows to the piston.
From pilot
reducing valve
SWG00423
From quick
return valve
-8
2?
From oilot
reducing valve
10-29-12
0
EMERGENCY
SPOOL
Function
.
If there is any failure in the electrical circuit
of the transmission
control system, and the
solenoid valve does not work, the emergency
spool is used. This spool is attached to each
directional and speed spool and is used to
operate the transmission valve mechanically.
(It is used to drive the machine to a place
where it can be repaired.)
*
Particular
attention
must be paid for
when using this spool.
Operation
1. When solenoid valve is normal:
(Emergency spool is at normal position)
When the solenoid valve is working normally,
the spool is maintained
in this position.
Oil from directional and speed spool (1) enters port A, but it is shut off by solenoid
valve (2).
From quick
return valve
5/t,
Kh
:
:
%
From Pilot
reducing
valve
2.
When solenoid valve is abnormal:

a. Clutch in disengaged position
(Emergency
manual spool is pushed to
the left (at normal position))
Emergency
spool (3) is pushed to the
left, and the oil at port A is shut off regardless of the action of solenoid valve
(2). The oil cannot flow to port B, so the
clutch is not actuated.
From quick
return valve
,
:,,,
KL
:
:
From Pilot
reducing
valve
Clutch in engaged position

(Emergency spool is pulled to the right
(at actual position))
When emergency
spool (3) is pulled to
the right, the oil at port A is drained to
port B regardless of the operation of solenoid valve (2). As a result, the clutch is
actuated.
b\
SWG00426
From quick
return valve
From oilot
reducina
valve
10-29-13
0
:
A
b.
SWG00425
SWG00427
INCHING
VALVE (INCHING
An inching
reduce
valve
with
the shock
VALVE WITH MODULATING
modulation
when
is employed
the inching
pedal
VALVE)
to
is oper-
From
Drain
ated.
OPERATION
1.
When
inching
The
valve
oil from
the
is not depressed;
pump
and B, goes through
passes
through
the F-R spool
ports
and is sent to
the F-R clutch.

The
return
valve
spring
spool
of the
(2) and collar
to the right.
The oil passing
ters chamber
prevents
valve
The
oil in chamber
shut
off by spool
pedal
pushes
push valve
through
C, and produces
(1) to the left. However,

spring
inching
(3). These
orifice
(1)
D en-
force
to push valve
the tension
of the return
(I) from
Modulating
valve
moving.
E of the
modulating
(2), so it does
valve
not flow
is
From pump
To oil cooler
bypass valve
to drain
port F.
2.
When
235FO2006
inching
When
the
valve
spool
valve
the
clutch
of
the
between
modulating
to port
the
tension
drain
In other
and the
is reduced,
In addition,
port
F and
(7) is opened
the oil in chamber

is drained.
hole
pressure.
engaged.
valve
E passes
Modulating
G, and
the
of
in cham-
B is throttled
F-R clutch
is partially
drain
(1) to the left to a
with
F-R clutch
the passage
pressure
and
valve
it balances
ber C becomes
the
pas-
chamber
by spool
through
valve
main
so
the
E of
(2), so
the throttle
(7) moves
pressure
is kept
to
re-
duced.
3.
When
inching
Valve
spool
valve
is fully
(2) moves
From pump
To oil cooler
bypass valve
235FO200:
depressed;
completely
to the
the tension
of spring
(5) is further
result,
hydraulic
pressure
the
From pump
Drain
depressed,
(5) and (6), and the oil pressure
words,
sage
depressed;
is slightly
to the left, so the oil press-
C pushes
where
springs
pedal
(2) moves
ure in chamber
position
is slightly
inching
reduced.
of the
left,
so
As a
D:i
5 From pump
F-R clutch
drops to 39 - 49 kPa (0.4 - 0.5 kg/cm2}, and the clutch

is completely
The
disengaged.
oil at port
nected
to drain
E of modulating
circuit
valve
F, so the main
(7) is conpressure
is
kept reduced.
4.
Inching
valve
If spool
port
(closed
(2) closes
E continues
-+ open)
drain
to push

circuit
rises and returns

this happens,
is engaged
F, the oil entering
modulating
and the pressure
When
F-R clutch
circuit
valve
(7) to
Modulating
valve
in the main
to the set pressure.
modulation
smoothly.
is applied,
so the
To oil cooler
bypass valve
From pump
235FO2008
10-29-14
0
STRUCTURE
AND
FUNCTION
TRANSMISSION
Serial
TRANSMISSION
CONTROL
No.: 11001 - 11030
lIn
rd
II
I..l
235COO2002
1.
Bolt
7. Rotary
3. Reverse
8. Connector
4. Forward
5. Button
1O-30
0
6. Gear shift lever
2. Shift lock lever

switch
switch
switch
switch
9. Interlock
10. Interlock
lever
CONTROL
STRUCTURE
AND
TRANSMISSION
FUNCTION
CONTROL
l-l
A-A
6-B
lJ
235CD02003
Outline
l
The
control
system
of this
machine
electrical
type.
So, the operation
operating
force
and stroke
When
operating
switching
gear
range
is used
rotary
is sent
to each
transmission
control
shift
switch
lever
(6),
(7), and the

valve
Press button
when
moving
switch
the
F-R
current
so that
the
If gear
shift
and shift
tion,
bolt
(5) on the gear shift lever only
the gear shift
(for both forward
(3), (4) and the speed
solenoid
valve
the
and the
are small.
is used F-R switch
signal
is used
is easy
lever
5 .+ 6 or 6 + 7
and reverse).
lever
lock lever
(1) holds
(6) is placed
at the
(2) is placed
gear
shift
N position
at the LOCK posi-
lever
(6) and keeps
the gear shift lever in the N position.
operates.
10-31
0
TRANSMISSION
Serial No.: 11031 - 12012, 12016 - 12018
1. Bolt
6. Gear shift lever
2. Shift lock lever
7. Rotary
3. Reverse
8. Connector
4. Forward
5. Button
10-31-l
0
switch
switch
switch
switch
9. Interlock
10. Interlock
lever
CONTROL
STRUCTURE
AND
TRANSMISSION
FUNCTION
CONTROL
c-c
A-A
SDGOOOO
1
Outline
The transmission
control is an electrical type.
When the shift lever is operated,
an electrical signal is sent to the transmission
solenoid valve from F and R switches (4) and (3)
when switching
direction,
and from rotary
switch (7) for the gear ranges, and the control valve is actuated.
.
To prevent
mistaken
operation,
when the
shift lever is operated
5 + 6 or 6 + 7 (both
forward
and reverse)
and when it is operated N tf P, button (5) installed to shift lever
(6) must be pressed to move the shift lever.
l
When shift lever (6) is at the N or P position,

and shift lock lever (2) is set to the LOCK
position,
bolt (I) holds shift lever (6) and
prevents
it from moving
back from the N
position
(1st and other drive positions).
10-31-2
0
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
SWG00350
Outline
.
The transmission
control is an electrical type.
When shift lever (1) is operated,
an electrical
signal is sent to the transmission
controller
from
F and R switches
(3) and (2) when
switching
direction,
and from potentiometer
(5) for the gear ranges.
The drive for the transmission
solenoid valve
is carried out by the transmission
controller
to protect
the transmission
from mistaken
operation
or failure in the control system.
To prevent mistaken operation, when shift
lever (1) is operated N ++ P, button (4) installed to the shift lever must be pressed to
move the shift lever.
l
10-31-4
0
INCHING
CONTROL
_--_I@
2-
A-A
T
D
l-
F
---
235CDO2004
1.
Inching
2.
Brake pedal
pedal
3.
Brake valve
4.
Transmission
1 O-32
control
valve
!!
:I
DRIVE
SHAFT
-I6
-
:::
d----.
_
h
:P
F23501019
1.
Drive shaft
1o-33
STRUCTURE
AND
FUNCTION
FINAL DRIVE, DIFFERENTIAL
FINAL DRIVE, DIFFERENTIAL
LOCK AND
UNLOCK
PIPING
LOCK AND UNLOCK PIPING

t
II
A=========3
ii
SWG00351 +
1o-34
0
STRUCTURE
AND
FUNCTION
FINAL DRIVE,
DIFFERENTIAL
LOCK AND
UNLOCK
PIPING
SWG00352
[A
SWG00353
1.
2.
A-A
3.
4.
5.
Differential lock pump (LAL 12)

Relief valve
Set pressure: 2.5 MPa (25 kg/cm*}
Solenoid valve
Differential lock piston
Bearing lubrication
1o-35
0
FINAL DRIVE
i
16
15
14
12
13
A-A
1. Shaft
2. Sprocket
(21 teeth)
3. Side case
235COO2006
7. Case
13. Gear (20 teeth)
8. Bevel gear (59 teeth)
14. Ring gear (78 teeth)
9. Coupling
15. Gear (28 teeth)
4. Flange
IO. Bevel pinion
5. Shaft
11. Disc
6. Gear (21 teeth)
12. Plate
1O-36
0
11
(16 teeth)
16. Pin
235CD02007
17.
18.
19.
20.
Filler tube
Oil level gauge
Breather
support
Outline
When motor graders carry out operations with
the blade angled to the front or the chassis at
an angle, there is a reaction to this. It applies a
force in a sideways direction from the front, and
the machine tries to turn to the left or right.
It is necessary to give the machine the ability to
resist this and travel in a straight line, so generally speaking, motor graders are not designed
to be equipped with a differential.
However, the GD825A is an articulated type, so
when the machine is articulated, the rear wheels
tend to slip to the side. For this reason, the
machine is equipped with a differential to improve the wear resistance of the rear tires. Control of the differential can be carried out simply
by pressing a switch in the operators compartment.
Operation
The power transmitted
from the engine to the
transmission
is then transmitted
by the meshing of bevel pinion (IO) and bevel gear (7), and
is sent from shaft (6) -+ (I) + sprocket (2).
The differential and differential lock are switched
hydraulically
by the contact between disc (11)
and plate (12).
whee
To
front
wheel
\
1o-37
0
023502
Serial No.: 11001 12021
1.
2.
3.
4.
5.
6.
7.
Chain
Breather
Shaft
Sprocket
Cage
Piston
Spring
8.
9.
10.
11.
12.
13.
14.
Gear (105 teeth)

Plate (138 teeth)
Disc
Tandem case
Sprocket
Oil level gauge
Drain plug
10-39
(6)
023502
1.
2.
3.
4.
5.
6.
7.
10-40
(6)
Chain
Breather
Shaft
Sprocket
Cage
Piston
Spring
8.
9.
10.
11.
12.
13.
14.
Gear (105 teeth)

Plate (138 teeth)
Disc
Tandem case
Sprocket
Oil level gauge
Drain plug
STEERING
PIPING
STEERING
1.
2.
3.
4.
5.
6.
SWING
CIRCLE
PIPING
Steering cylinder (R.H.)

Steering cylinder (L.H.)
Double relief valve
Steering valve
Check valve
Check valve
10-41
0
STEERING CIRCUIT SYSTEM
I
235FO2011
1.
Pump
2.
Servo
7. Check valve
flow devider
valve
piston
8. Priority
valve
9. Hydraulic
control
valve
(R.H.)
4.
Check valve
10. Hydraulic
control
valve
(L.H.)
5.
Steering
valve
6.
Steering
cylinder
3.
1 O-42
Servo
11. Surge
pressure
absorbing
valve
STEERING CIRCUIT DIAGRAM
From hydraulic
control valve
-c--
To hydraulic
control valve
t
235FO2012
1. Hydraulic
8. Steering
tank
2. Strainer
3. Hydraulic
4. Priority
pump
flow
devider
7. Check valve
relief valve
IO. Steering
cylinder
11. Breather
12. Surge
5. Check valve
6. Last chance
valve
filter
valve
9. Double
pressure
13. Pressure
14. Emergency
absorbing
valve
switch
pump
1o-43
STRUCTURE
AND
STEERING
FUNCTION
VALVE
STEERING VALVE
ORBIT-ROLL
A-A
10
11
SEW01234
1.
2.
3.
4.
Needle bearing
Center spring
Drive shaft
Valve body
1o-44
0
5.
6.
7.
8.
Rotor
Cover
Center pin
Sleeve
9.
10.
11.
12.
Spool
Stator
Lower cover
Check valve
STEERING VALVE
Outline
l
The steering valve is connected directly to

the shaft of the steering wheel. It switches
the flow of oil from the steering pump to the
left and right steering cylinders to determine
the direction of travel of the machine.
The orbit-roil valve, broadly speaking, consists of the following
components:
rotary
type spool (9) and sleeve (81, which have the
function of selecting the direction, and the
Girotor set (a combination
of rotor (5) and
stator (IO)), which acts as a hydraulic motor
during normal steering operations, and as a
hand pump (in fact, the operating force of
the steering wheel is too high, so it cannot
be operated)
when the steering pump or
engine have failed and the supply of oil has
stopped.
SLWO1980
Structure
l
Spool (9) is directly connected to the drive

shaft of the steering wheel, and is connected
to sleeve (8) by center pin (7) (it does not
contact the spool when the steering wheel
is at neutral) and centering spring (2).
The top of drive shaft (3) is meshed with
center pin (7), and forms one unit with sleeve
(81, while the bottom of the drive shaft is
meshed with the spline of rotor (5) of the
Girotor.
There are four ports in valve body (41, and
they are connected to the pump circuit, tank
circuit, and the circuits at the head end and
bottom end of the steering cylinders. The
pump port and tank port are connected by
the check valve inside the body. If the pump
or engine fail, the oil can be sucked in directly from the tank by this check valve.
Connected
steerlnu
wheel
shaft
Groove
with
for
center
to
meshins
Pin
1o-45
0
STRUCTURE
AND
CONNECTION
FUNCTION
BETWEEN
STEERING
HAND
VALVE
PUMP AND SLEEVE
SBWOO725
SBWW726
The diagrams above show the connections

with the sleeve ports used to connect the
suction and discharge ports of the Girotor.
If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected
by the vertical grooves in the spool to the
pump side. At the same time, ports b, d, f,
h, j, and I are connected to the head end of
the left steering cylinder in the same way.
In the condition in diagram above left, ports
1, 2, and 3 are the discharge ports of the
Girotor set. They are connected to ports I, b,
and d, so the oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90, the condition changes to the condition shown in
diagram above right. In this case, ports 1, 2,
and 3 are the suction ports, and are connected to ports i, k, and c. Ports 5, 6, and 7
are the discharge ports, and are connected
to ports d, f, and h.
1O-46
0
Suction /
diTrge
port
SBWGO727
SBWCQ728
STRUCTURE
AND
FUNCTION
STEERING
VALVE
In this way, the ports of the Girotor

acting
as delivery
ports are connected
to ports
which are connected
to the end of the steering valve spool. The ports acting as suction
ports are connected
to the pump circuit.
Adjusting
delivery
in accordance
with angle
of steering
wheel:
For every Ii7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
position
so the oil flow from the pump is
adjusted
by this movement.
In this way, the
oil delivered
from the pump is directly
proportional
to the amount
the steering
wheel
is turned.
FUNCTION OF CENTER SPRING

.
Centering
spring (2) consists
of four layers
of leaf springs crossed to form an X shape.
The springs are assembled
in spool (9) and
sleeve (8) as shown in the diagram
on the
right.
When the steering wheel is turned, the spring
is compressed
and a difference
in rotation
(angle variation)
arises between
the spool
and the sleeve.
Because of this, the ports in the spool and
sleeve are connected
and oil is sent to the
cylinder.
When the turning
of the steering
wheel is stopped, the Girotor also stops turning, so no more oil is sent to the cylinder
and the oil pressure rises.
To prevent
this, when the turning
of the
steering
wheel is stopped,
the action of the
centering
spring only allows it to turn by an
amount
equal to the difference
in angle of
rotation
(angle variation)
of the sleeve and
spool, so the steering
wheel returns to the
NEUTRAL position.
Angle
variation
sow0230 I
1o-47
0
DOUBLE
RELIEF VALVE
(For Steering)
1.
2.
3.
4.
5.
6.
7.
Relief valve
Body
Poppet(B)
Sleeve
Relief valve
Poppet (A)
Sleeve
FL?3501389
ll4-n
F238098
The check valve with safety valve protects the cylinder from abnormal
pressure inside the cylinder
caused by external force.
OPERATION
In the hydraulic circuit diagram above, oil from chamber A, enters. When there is abnormal pressure of
over 210 kg/cm2, it pushes poppet (A) and flows to
chamber A,. In the same way, when there is abnormal
pressure of over 210 kg/cm2, oil from chamber Bz
pushes poppet (B) and flows to chamber B 1.
F23BOSS
1 O-48
CHECK VALVE
1.
Nipple
2.
Joint
3.
Spring
4.
Valve
235FO2013
235FO2014
-8
FJJ
__-
1.
*I
Joint
2.
Spring
3.
Valve
4.
Nipple
ZJ
I
I
+---~\,L-__-------f
+1
rX-
---------
LI
_Jk
,
*
235FO2015
F23501391
1o-49
EMERGENCY STEERING SYSTEM
235FO2017
235FO2016
OUTLINE
.
If the oil pressure
in the hydraulic
0.7 MPa (7 kg/cm2)
because
gine or the pump,
pressure
ON, and emergency
pump
it possible
*
of a failure
switch
drops
to
in the en-
(3) is switched
(1) is actuated
to make
to steer the machine.
If the travel
chine
circuit
speed
is stopped,
is below
1 km/h
the emergency
or the ma-
steering
sys-
tem is not actuated.

*
The emergency
pump
do not continue
to operate
seconds.
1O-50
is an electric
pump,
so
it for more than 30
1.
Emergency
2.
Speed
pump
sensor
3.
Pressure
4.
Relay
5.
E.S.C controller
6.
Buzzer
7.
Select
8.
Starting
switch
switch
motor
STRUCTURE
AND
FUNCTION
FRONT AXLE
FRONT AXLE
Serial No,: 11001 - 12050
A-A
B-B
c-c
D-D
235CDO2009
1. Steering
cylinder
2. Tie rod
6. Housing
7. Bracket
3. Front axle
8. Leaning
4. Leaning
9. King pin
5. Hub shaft
cylinder
rod
10. Hub nut
1o-51
0
FRONT AXLE
023502
Serial No.: 12099 12502
10-51-2
(6)
FRONT AXLE
023502
10-51-3
(6)
WHEEL
Serial No.: 11001 - 12000
FRONT WHEEL
(OPT)
*\
3A
1.
2.
3.
Side
Rim
Tire
ring
F23501039
F23501040
Tire size
18.00-25-I 2PR
Tire size
Rim size
13.00 x 25TB
Rim size
Air pressure
0.25 MPa (2.60 kg/cm*}
REAR WHEEL
23.5-25-12PR
19.5 x 25WTB
Air pressure
0.24 MPa 12.46 kg/cm*}
(OPT)
042
=23501041
Tire size
Rim size
Air pressure
1o-52
0
18.00-25-l 2PR
Tire size
23.5-25-l 2PR
13.00 x 25TB
Rim size
19.5 x 25WlB
0.25 MPa i2.60 kg/cm21
Air pressure
0.24 MPa 12.46 kg/cm21
2
FJ
g

FRONT WHEEL
(OPT)
*\
l----1.
2.
3.
Side ring
Rim
8H
Tire
:23501039
F23501040
Tire size
Rim size
Air pressure
23.5-25-12PR
Tire size
18.00-25-12PR
19.5 x 25WTB
Rim size
13.00 x 25TB
0.24 MPa f2.46
kg/cm*}
REAR WHEEL
0.25 MPa t2.60
Air pressure
kg/cm3
(OPT)
F2350
F23501042
1041
Tire size
23.5-25-12PR
Tire size
18.00-25-I
Rim size
19.5 x 25WTB
Rim size
13.00 x 25TB
Air pressure
1 0.25 MPa I2.60 kg/cm?
Air pressure
1 0.24 MPa 12.46 kg/cm?
2PR
10-52-l
0
DISC BRAKE
STRUCTURE
OF DISC BRAKE
1234
I II
Final drive
F23501056
Disc brakes are fitted

actuated
The
shaft
motive
(I),
on the four rear wheels
and are
by air pressure.
force
from
1. Hub shaft
2. Gear
the final
drive
rotates
gear (2) and disc (4). This rotation
hub
is trans-
3. support
4. Disc
mitted to the tires which are fixed to the hub.
5. Plate
Each brake
6. Spring
consists
of discs (4) which
are meshed
with gear (2). plates (5) which
are meshed
with cage
7. Cage
(7) and piston
are cooled
by the oil
8. Piston
(8). The
inside the tandem
case.
discs
9. Nut
IO. Bolt
1o-53
OPERATION
1.
Brake applied
When
the brake pedal is depressed,
is connected
When
force
the air pressure

of spring
and pushes
generated
between
(2)) and the plates

slows
down
is greater than the pushing
(6), piston
discs
the air circuit
A of the disc brake.
to chamber
(8) moves
(41 and plates
the discs (meshed

(meshed
the rotation
stops it. In other words,
with
to the left,
(5). Friction
is
with gear
cage (7)). This
of the discs and finally

the brake is applied.
From air tank
8
F23501057
Brake released
When
the
brake
pedal
is released,
chamber
A is released.
Spring
(8)
to the
so the
back
reduced.
discs
This
(4)
rotate
and
freely.
right,
removes
plates
In
(5),
other
the
the
(6) moves
pushing
friction
and
words,
air in
piston
force
is
between
allows
them
to
the
brake
is
released.
To air tank
F23501058
1o-54
PARKING BRAKE
Section A -A
F23501061
Outline
l
The
1.
parking
brake is a disc type and is installed
on the transmission
l
The force
output shaft.
of the spring inside the spring cylinder
(7) is used to apply the brake mechanically;

released
l
it is
by air pressure.
When
spring cylinder
juster
(6)
and
shaft
(7) yoke is moved out, ad(5)
turn
(3) and plate
and
piston
moves.
So discs
contact
and the parking brake is applied.
(2) are forced
Disc
2.
Plate
3.
Disc
4.
Piston
5.
Shaft
6.
Adjuster
7.
Spring cylinder
(4)
in
1o-55
STRUCTURE
AND
BRAKE AIR PIPING
FUNCTION
BRAKE AIR PIPING
II
1.
2.
3.
4.
5.
6.
Brake valve
Disc brake housing
Safety valve
Air governor
Check valve
Parking brake
7.
8.
9.
10.
11.
Parking brake valve

Air tank
Air drier
Air compressor
Automatic drain valve
1o-57
0
BRAKE AIR CIRCUIT SYSTEM
235FO2018
11. Stop lamp switch
1. Air compressor
2. Air drier
12. Disc brake
3. Air governor
13. Tire charger
4. Check valve
14. Horn valve
5. Air tank
15. Horn
6. Safety
8. Pressure
switch
gauge
9. Automatic
10. Brake valve
1 O-58
16. Parking
valve
7. Low pressure
drain valve
socket
brake valve
17. Exhaust
valve
18. Parking
brake
19. Bank-lock
valve
20. Bank-lock
cylinder
BRAKE AIR CIRCUIT DIAGRAM
SllG00003
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Air compressor
Air drier
Air governor
Check valve
Air tank
Safety valve
Low pressure switch
Pressure gauge
Automatic
drain valve
Brake valve
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Stop lamp switch

Disc brake
Tire charger socket
Horn valve
Horn
Parking brake valve
Exhaust valve
Parking brake
Bank-lock valve
Bank-lock
cylinder
1o-59
0
AIR DRIER
F23501047
The function
from
protects
vents
of the air drier is to remove
the compressed
air in the circuit.
the components
problems
with
of the equipment
operation
1.
the moisture
In this way
it
and pre-
in cold areas.
To Brakevalve
235FO2019
lo-60
Purge tank
2.
Check
3.
Spring
4.
Drier cylinder
5.
Drying
6.
Body
7.
Valve
8.
Valve
valve
agent
body
9.
Oil filter
A.
Air compressor
8.
Air drier
C.
Air governor
D.
Air tank
OPERATION
1.
Drying
When
the compressor
compressor
enters
then cooled
and water
(6).
The
which
is working,
by the outside
and oil collect
air then
is fitted
passes
with
before
Any water
through
air enters
(5). When
drier cylinder
then
the
oil filter
through
(9)
Here
cylinder
(4).
in the air is removed

the air reaches
check
To air tank
of dust are re-
drier
(4). it is completely
passes
(4).
of body
an oil mist separator.
still included
drying agent
the
It is
of drier cylinder
in the bottom
the fine drops of oil and particles

moved
air from
port A of the air drier.
by
the top of
dry. This dry air
valve
(2) and purge
From air compressor
tank (1) to the air tank.
F23501048
2.
Restoring
When
drying
agent
the air pressure
the set pressure,

compressor
received
Valve
inside the circuit
the air governor
to unloading.
by the
(8) opens
(4) is released
control
reaches
switches
The
governor
ports
of the
the
is also
air drier.
and the air inside drier cylinder
to the atmosphere.
This drops the
air pressure
in purge tank (I 1, and the dried air in
purge
(I)
tank
passes
through
cause of the drop in pressure,

and
becomes
through
drying
dry more.
drier cylinder
agent
closes,
the
and
loading
the
Be-
As the air flows
back
from
is carried
This completely
agent (5) and prepares

When
a.
(41, it picks up water
(5) and the water
the atmosphere.
orifice
the dry air expands
it for further
cycle
air drier
starts
returns
out to
dries out drying

use.
again,
valve
to the
(8)
drying
action.
From air 9overnor
F23501049
10-61
AIR TANK
Section
The
air tank
duced
238FO66
A-A
acts
to store
the
compressed
air
pro-
by the air compressor.
Maximum
pressure:
0.93 MPa (9.5 kg/cm*)

(Capacity
17.5 P x 2)
SAFETY VALVE
238FO67
The safety
maintain
inside
kg/cm)
valve
safety
the air tank exceeds

the safety
the atmosphere.
1 O-64
is installed
in the air tank and acts to
in the air circuit.

valve
When
the
pressure
0.93 f 0.04 MPa (9.5 + 0.4

releases
compressed
air to
1.
Valve
2.
Ball
seat
3.
Release
4.
Spring
pin
5.
Spring
6.
Lock nut
cage
7.
Adjusting
screw
1.
Plate
2.
Plate
3.
Plate
4.
Boss
AUTOMATIC
DRAIN
2
VALVE
I.
2.
3.
4.
5.
6.
7.
Retainer
Filter
Body
Plug
Valve guide
Inlet-Exhaust
Cover
valve
238FO72
The automatic drain valve is installed at the bottom

of the air tank. It acts to automatically
drain any
water which forms when the compressed
air is
cooled.
OPERATION
1. When there is no air pressure inside the air tank,
inlet-exhaust valve (6) is closed.
238FO73
1O-65
2.
When
air
exhaust
pressure
valve
enters
16) opens
is low. Air and water

inlet-exhaust
inside
valve
then
stops
the air tank reaches
(until the governor
the
air
even when
enter
open
tank,
inlet-
the pressure
chamber
A. The
until the pressure
the maximum
pressure
is cut off).
238FO74
3.
When
the pressure
sure in chamber
valve
guide
in the air tank
A are equal,
(5) closes
and the pres-
the spring
inlet-exhaust
action
valve
of
(6).
238FO75
4.
When
the pressure
pressure
cm2), inlet
in chamber
exhaust
in the air tank

A is about
valve
drops,
and the
0.03 MPa (0.3 kg/
(6) exhausts
the air and
water.
238FO78
1O-66
CHECK
VALVE
1
1.
PI
PZ
Body
2.
Disc valve
3.
Spring
4.
Screw
cap
238FO64
The
check
valve
from flowing
compressor
acts to prevent
air in the air tank
back to the air compressor
when the air
is stopped.
OPERATION
When
air flows
into the check
valve
valve (2) leaks its seat and the air flows
from
the left,
freely to the
various ports.
When
valve
air flows
into the check
(2) is pushed
back
valve from
into its seat
the right,
by spring
(3)
and the air pressure. This shuts off the air flow.
238FO65
1 O-67
BRAKE VALVE
--. /
4L
ix
i
1,
l\ 0
\__,
/
i
,I--,
:
\ 0,
ii
._.
l--r---___--_____r_~_
F23501050
1.
235FO2020
1O-68
2.
3.
4.
5.
6.
7.
Brake pedal
Plunger
Piston
Inlet valve
Piston
Inlet valve
Rubber spring
A.
B.
C.
D.
From air tank

From air tank
To R.H. relay valve
To L.H. relay valve
OPERATION
1.
Brake
operating
Upper
part
When
brake
operating
rubber
spring
operating
l
pedal
force
When
is depressed,
plunger
(71, and
these
the
(2)
and
transmit
the
force to piston (3).
piston
haust outlet
down
(1)
pushes
(3) moves
down,
it closes ex-
(9). At the same time, it pushes
inlet valve
(4) and air flows
from
air
air flows
to
tank A to right relay valve C.

Lower
l
part
When
inlet
chamber
l
valve
(4)
The air pressure
pushes
this closes exhaust

time,
it pushes
flows
from
actuate
l
Only
needed
opens,
a of piston (5).
piston (5) down and
outlet
(I 0). At the same
down.inlet
valve
(6) and air
air tank B to left relay valve D to
the brake.
a
small
amount
of
air
pressure
is
to move piston (51, so the movement
of the lower valve occurs at almost the same

time as the movement
of the upper valve.
F23501051
2.
Brake
operation
when
lower
side
breakes
down
If there is any leakage
upper
side operates
does not actuate
of air at the lower side, the

normally
but the lower
side
the brake.
F23501052
lo-69
3.
Brake operation when upper side breaks down

.
If there is any leakage of air at the upper
side, piston (5) is pushed down mechanically
when
the brake pedal is depressed.
Because
of this, the lower side operates
normally
the upper side does not actuate
the brake.
but
F23501053
4.
Balancing
Upper
operation
part
If the air pressure
in relay valve
space below piston (3) becomes

(3) will push rubber
spring
C and the
high, piston
(7) and move up
to close inlet valve (4).

l
When
this
happens,
mains closed,
exhaust
outlet
so the air pressure
valve is maintained.
(9) re-
in the relay
As a result, the brake re-
mains applied.
Lower
l
part
When
the air pressure
of piston
at the top and bottom
(5) becomes
slightly
the same, the piston
moves
down
under the force
spring
at the top of the
piston
inlet valve (6). The exhaust

the
air pressure
and closes
valve is closed so
is maintained.
As a result,
the brake remains applied.

l
The
pressure
balances
with
in the space
the
in the upper
operating
pedal,
and the pressure
lower
part balances
of the
force
in the space
part
of
the
in the
with the air pressure
in
t-i
the space in the upper part.
F23501054
1O-70
When
piston
stroke
inlet valves (4) and (6) are completely
opened.
(3) and
As a result,
spaces
(5) move
the air pressure
in the right and left relay valves

Therefore,
down,
in the
until
is the same
in the air reservoir.

the
the braking
amount
5.
whole
in the upper part and lower part, and
as the air pressure

l
their
piston
effect
its full
stroke
is controlled
by the
the brake pedal is depressed.
Pedal released
Upper part
l
If the pressure
the operating
on the pedal
pressure
top of the piston,

cause
the piston
of the air pressure
the piston and the force

spring.
As a result,
port (9) is opened
is reduced,
is removed
moves
the
up be-
at the bottom
of
of the piston return
the passage
to exhaust
and the compressed
the relay valve is released
and
from
air in
to the atmosphere.
Lower part
l
If the pressure
the compressed
released,
the
on the pedal is reduced,

air pressure
at the bottom
piston (5) pushes piston (5) up. Exhaust

(10)
is opened
and
air at the top of piston (5) is
and the compressed
relay valve is released
of
port
air in the
to the atmosphere.
F23501055
10-71
PARKING BRAKE SYSTEM
235CD02012
From air tank
235FO2022
235FO2021
OUTLINE
If the
LEASE
parking
brake
position,
solenoid
the air pressure

cylinder
l
switch
from
(3) to release
ING position,
solenoid
in spring
valve
by the
brake.
1 O-72
cylinder
1.
Parking
brake solenoid
RE-
2.
Exhaust
valve
and
3.
Spring
spring
brake.
at the PARK-
(1) is closed
and the
the air tank is shut off, so the air

(3) is discharged
(2), and the spring

force
pushes
is placed
valve
at the
(1) is opened
the parking
brake switch
from
valve
the air tank
If the parking
air pressure
is placed
of the
cylinder
spring
from
exhaust
is pushed
to apply
the
back
parki_ng
cylinder
valve
PARKING BRAKE SOLENOID
VALVE
1.
Coil
2.
Body
3.
Inlet valve
4.
Outlet valve
A.
Inlet port
B.
Outlet port
C.
From air tank
423F119
Function
l
The
parking
brake
solenoid
valve
is a valve
to
switch air to the parking brake spring cylinder.
Parking brake operated

When
the shift
position,
current
the solenoid
flows),
spring
valve is switched
OFF (no
the tank enters
port C is sealed by valve (4). so
out. The
cylinder
air in the
is drained
around
port E. Therefore,
valve
parking
through
valve. The air from the exhaust

A, passes
to the PARKING
and the air from
port C. However,
no air flows
Spring
lever is moved
the
brake
exhaust
valve enters
(5) and is drained
port
from
Exhaust Gz!
From are
tank
the spring force of the parking
235F239-1
brake spring cylinder applies the parking brake.
Parking brake released

If the
shift
PARKING,
lever
is at any
solenoid
valve
position
other
is ON (current
and valve (5) moves down. Valve
then
flows),
(4) is connect-
ed to valve (5) by a rod, so valve (41 also moves

down.
The air from the tank enters port C, and valve (4)
has moved
(4).
down,
so the air passes around valve
It then flows from port A through
valve
to the
parking
release the brake.
brake
spring
the exhaust
cylinder
From air
tank
to
235F240-1
1o-73
EXHAUST VALVE
Section
A-A
z
4
2
F23501060
1.
When
moved
Rubber valve
3.
Valve
4.
Cap
A.
To spring cylinder
B.
Exhaust
C.
From solenoid valve
the
through
Body
2.
the
and
port
compressed
solenoid
opens
air
valve,
the circuit
and A and then the air flows
When
this happens,
When
no air flows
spring cylinder
moves
haust
to
port
valve
between
(2) is
ports
to spring cylinder.
the parking brake is released.

to port C, the
air from
the
is sent to port A so that valve (3)
to the right and the air is released

port
B. When
brake is applied.
1o-74
flows
rubber
this
happens,
the
to exparking
SPRING CYLINDER
423F
1.
2.
3.
4.
5.
Rod
Boot
Cylinder
Spring
Piston
I 24
OUTLINE
The air pressure from the parking brake solenoid valve pushes spring (4) and compresses it to release the parking brake.
Usually the parking brake is kept applied by
spring (4), so the machine is prevented from
moving.
l
1o-75
0
HYDRAULIC CONTROL PIPING
HYDRAULIC
CONTROL PIPING
LOW AND HIGH PRESSURE PIPING
A-A
1O-76
0
1.
2.
3.
4.
5.
6.
L.H. hydraulic
control valve
R.H. hydraulic
control valve
Main relief valve
Priority flow divider valve
Hydraulic
pump
Hydraulic
tank
1o-77
0
STRUCTURE
AND
HYDRAULIC
FUNCTION
CONTROL
HIGH PRESSURE PIPING

Serial No.: 11001 - 12050
-___
4
7
i
1.
2.
3.
4.
5.
--__-
Pilot check valve (for articulate)

Articulate
cylinder
L.H. hydraulic
control valve
Pilot check valve (for blade lift) L.H.
Pilot check valve (for power tilt)
1 O-78
0
: :
I i
6.
7.
8.
9.
10.
R.H. hydraulic
control valve
Blade lift cylinder
Pilot check valve (for leaning)
Pilot check valve (For drawbar
Leaning cylinder
shift)
PIPING
STRUCTURE
AND
FUNCTION
HYDRAULIC
Ii
11.
12.
13.
14.
15.
Pilot check valve (for blade lift) R.H.

Shuttle valve
Circle rotation motor
Power tilt cylinder
Circle rotation gear
CONTROL
PIPING
SWGOO
359
16. Swivel joint

17. Drawbar side shift cylinder
18. Blade side shift cylinder
1o-79
0
STRUCTURE
AND
HYDRAULIC
FUNCTION
CONTROL
PIPING
II
IO
SWGOO
1.
2.
3.
4.
5.
Pilot check valve (for articulate)

Articulate
cylinder
L.H. hydraulic
control valve
Pilot check valve (for blade lift) L.H.
Pilot check valve (for power tilt)
10-79-l
0
6.
7.
8.
9.
10.
R.H. hydraulic
control valve
Blade lift cylinder
Pilot check valve (for leaning)
Pilot check valve (for drambar
Leaning cylinder
shift)
1360
18
11.
12.
13.
14.
15.
Relief valve (for leaning)

Pilot check valve (for blade lift) R.H.
Circle rotation motor
Circle rotation gear
Power tilt cylinder
SWG00361
16. Swivel joint

17. Drawbar side shift cylinder
10-79-2
0
HYDRAULIC TANK PIPING
ii
ii
235COO2013
1.
Return
2.
Suction
3.
Hydraulic
1o-79-3
0
filter
filter
pump
STRUCTURE
AND
FUNCTION
HYDRAULIC
CONTROL
PIPING
RIPPER PIPING
__----
235COO2016
1.
Ripper
2.
Pilot check valve
cylinder
1o-79-4
0
STRUCTURE
AND FUNCTION
HYDRAULIC
Engine running,
HYDRAULIC
CIRCUIT
SYSTEM
CIRCUIT SYSTEM
work
equipment
control
lever in HOLD
1x1
x3
1x4
235FO2023
1.
Servo
valve
5.
Steering
2.
Servo
piston
6.
Hydraulic
3.
Pump
7.
Surge
4.
Priority
8.
Hydraulic
1O-80
0
flow
divider
valve
valve
control
pressure
control
valve
(L.H.)
absorbing
valve
valve
(R.H.)
STRUCTURE
AND
HYDRAULIC
FUNCTION
HYDRAULIC
CIRCUIT
DIAGRAM
CIRCUIT DIAGRAM
Serial No.: 11001 - 12022

27.4MPa
~280kdcm~l
IO
_______
L.lI!ii
I/
L___
12
27.4MPa
(280wcm~t
27.4MPa
(280Wcmzl
113
_-
----II-II
-1
I
t--
2:
r
1 O-80-2
0
1---1p
STRUCTURE
AND
FUNCTION
II
HYDRAULIC
II
II
CIRCUIT
DIAGRAM
II
3 -7+Q
I
I
I
4
5I
!I
i
------------7
<
I
I
; ---------------~~~_____-----__~_~--------_--------______---_________
I
24.5MPa
i250ko/cm*i
SWG00363
10-80-3
0
STRUCTURE
HYDRAULIC
AND FUNCTION
1. Hydraulic
tank
2. Breather
3. Strainer
4. Hydraulic
5. Priority
6. Surge
pump
flow
(VXD70-IF)
divider
pressure
7. L.H. hydraulic
valve
absorbing
control
valve
7A. Blade lift (L.H.) control

7B. Ripper
control
(5-spool)
spool
spool
7C. Blade side shift control

7D. Power
valve
tilt control
7E. Circle rotation
spool
spool
control
spool
7F. Relief valve

8. R.H. hydraulic
control
8A. Drawbar
valve
8B. Articulate
control
8C. Leaning
spool
8D. Service
spool
spool
8E. Blade lift (R.H.) control

8F. Relief valve
9. Blade lift cylinder
(L.H.)
10. Accumulator
11. Blade float
12. Ripper
solenoid
valve
cylinder

14. Power
tilt cylinder
15. Swivel
joint
16. Circle rotation

17. Drawbar
19. Leaning
motor
shift cylinder
18. Articulate
cylinder
cylinder

21. Pilot check valve
22. Check valve
23. Steering
valve
24. Double
relief valve
25. Steering
cylinder
26. Pressure
switch
27. Filter
28. Hydraulic
29. Emergency
1 O-80-4
0
(5-spool)
shift spool
filter
pump
(R.H.)
spool
CIRCUIT
DIAGRAM
STRUCTURE
AND
FUNCTION
HYDRAULIC
CIRCUIT
DIAGRAM
Serial No.: 12023 - 12050
27.4MPa
27.4MPa
~280ks/cm~l
27.4MPa
14
rl
16
24.5MPa
(250Wcm~l
--i-___
I
---i---.__.i..-.__.i.._..__i--__-_~j
ILS
.*+-m-------
22
1 O-80-6
0
27
HYDRAULIC CIRCUIT DIAGRAM
24.5MPa
3-----4
Il
SWG00365
10-80-7
0
1. Hydraulic
tank
2. Breather
3. Strainer
4. Hydraulic
5. Priority
6. Surge
pump
flow
(VXD70-IF)
divider
pressure
7. L.H. hydraulic
valve
absorbing
control
valve

78. Ripper
control
7D. Power tilt control

7E. Circle rotation
control
valve
8B. Articulate
control
spool
8D. Service
spool
(L.H.)
10. Accumulator
solenoid
valve
cylinder

14. Power
tilt cylinder
15. Swivel
joint
16. Circle rotation

17. Drawbar
19. Leaning
motor
shift cylinder
18. Articulate
cylinder
cylinder

22. Check valve
23. Steering
valve
24. Double
relief valve
25. Steering
cylinder
26. Pressure
switch
27. Filter
28. Hydraulic
filter
29. Emergency
30.
Relief
valve
1O-80-8
0
(5-spool)
spool
12. Ripper
spool
shift spool
8C. Leaning
11. Blade float
spool
spool
control
8A. Drawbar
(5-spool)
spool
spool
8. R.H. hydraulic
valve
pump
(R.H.)
spool
STRUCTURE
AND
FUNCTION
HYDRAULIC
CIRCUIT
DIAGRAM
27.4MPa
27.4MPa
(28Ok/cm'l
27.4MPa
(280kP/cmzl
7;
A4
25
_-
r i
As
L
10-80-10
0
!*-@L-------
_,
22 27
:--
A3
-_83 -.__-____
82 -._______
A2
Bl _
>
24.5MPa
L_
24.5MPa
,-
; -----------
----yq+_____
____________________----_---------~
id27
27
i
IO
, , __-------_j@_
12
10-80-11
0
STRUCTURE
AND
1. Hydraulic
HYDRAULIC
FUNCTION
tank
2. Breather
3. Strainer
4. Hydraulic
5. Priority
6. Surge
pump
flow
(VXD70-IF)
divider
pressure
7. L.H. hydraulic
valve
absorbing
control
valve

7B. Ripper
control
tilt control
7E. Circle rotation

8. R.H. hydraulic
control
valve
control
8C. Leaning
spool
8D. Service
spool
(L.H.)
10. Accumulator
11. Blade float solenoid
valve
cylinder

14. Power tilt cylinder
joint
16. Circle rotation

17. Drawbar
motor
shift cylinder
18. Articulate
19. Leaning
cylinder
cylinder

22. Check valve
23. Steering
valve
24. Double
relief valve
25. Steering
cylinder
26. Pressure
switch
27. Filter
28. Hydraulic
filter
29. Emergency
30. Relief
valve
31. Relief
valve
10-80-12
(5-spool)
spool
15. Swivel
spool
shift spool
8B. Articulate
12. Ripper
spool
spool
control
8A. Drawbar
(5-spool)
spool
spool

7D. Power
valve
pump
(R.H.)
spool
CIRCUIT
DIAGRAM
CLOSED
This
CENTER
machine
to supply
uses the CLSS
an oil flow
characteristics
actuator
the
system
to match
equipment
to the actuating
increases
SENSING
in the hydraulic
to each
of the work
corresponding
This
LOAD
This system
l
the
at a pressure
l
performance
and
(CLSS)
consists
Variable
of the following
displacement
components.
piston
pump
with
servo-valve
load.
working
SYSTEM
saves
Selector
valve
with
type
pressure
proportional
flow
control
function
l
the fuel consumption.
Reducing
compensating
valve
Advantages
(I 1 Constant
of work equipment
speed not influenced
by
engine speed.
Increase of operating
performance
(2)
Extension
and retraction
speeds of cylinder the
same.
(3)
Excellent fine control

performance
(4)
(6)
Saves
energy
Fine control
(I) Constant
fluenced
of
work
by engine
(2) Extension
and
equipment
speeds
Relief loss saving
speed
not
in-
of cylinder
the
same.
The flow
tion
control
is decided
and the difference
of the throttle.
difference
Even if the engine
in pressure
plate
angle
of the
pump
is constant,
mains the same.
1o-:-1
by the area of restric-
in pressure
is equal
variable
on either
speed
and
side
rises, the
the
displacement
so the delivery
Y/
speed.
retraction
loss saving
swash
piston
of the pump
re-
type
pressure
Selector valve with

proportional
flow
control function
Excellent control for

compound
operations
Reducing
(3)
Excellent
The
fine control
oil flow
performance
to each actuator
area E of the gap between

the selector
fluenced
and
spool of the control valve. It is not in-
60
each
medium
to
body
by the load, so the fine control
a large
move
is proportional
the valve
70%.
part
Therefore,
of the
speed
to
range is
it is possible
work
equipment
more
enable
to
at
precise
operations.
F23501073
(4)
Excellent
control for compound
During
compound
servo detects
trols the
type
the
the larger actuating
pump
delivery
pressure
pressure)
difference
on
The
valve
reducing
on the
side controls
both
valve to a constant
hydraulic
force and con-
pressure.
compensating
load (actuating
sure
operations.
operations,
sides
of
F23501074
selector
is the
operations.
Reducing type pressure

compensating valve
Variable displacement
piston pump
Selector valve with

proportional flow
control function
++
_-_-__c----
I
I
Actuating
(5)
To actuator
From actuator
Pump delivery pressure
control lever travel
the pres-
the
value, so the operation
same as for independent
Work equipment
IoW
t
A
pressure
f
Return
Oil flow
-w
F23501075
Control flow
Flow
control
to
match
each
part
of
work
x oil flow)
when
equipment
The
power
operating
cise
needed
movement,
which
needs
viously
(pressure
the blade lift cylinder,

and
speed
different.
the gap explained
when
which needs pre-
rotating
and rotation
With
the CLSS,
(cylinder
speed)
12) Extension
circle,
is ob-
if the area of
in (3) Fine control
a large flow of oil can be supplied.
the
torque,
is increased,
Or, the oil flow
can be set in the same way for
and retraction
speed of cylinder.
(6)
Saves energy
The CLSS is a system
the necessary
Compared
in which the pump delivers
oil flow at the necessary
to the hydraulic
pumps, the loss of hydraulic

energy is extremely
pressure.
circuit used with gear

power
and hydraulic
small.
Gear pump
CLSS
In neutral
CLSS
Gear pump
During fine
control
Pump delivery amount

Only an oil flow to replace
the oil which leaks from
the high pressure circuits
of the valve and pump to
the lower pressure circuit is
needed. In addition, the
delivery pressure is the
standby pressure, so the
power loss is small.
The pump is always

delivering oil, and pressure
is caused by the resistance
in the piping circuit, so the
power loss is large.
Both the pump delivery

pressure and delivery
amount are controlled, so
the power loss is small.
The pressure corresponds

to the load, but only part c
the delivery amount is
used, so the power loss is
large.
The pump delivery

pressure is kept low, so the
power loss is small.
The pump delivery

pressure depends on the
load, so the power loss is
small.
The hydraulic servo acts to All the oil delivered from

the pump is wasted, so the
prevent the pump delivery
pressure from going above power loss is extremely
large.
the relief pressure, so the
oil flow is reduced and the
power loss is imall.
F
(1
Uunderno load)
P:
0:
m
Pressure
Oil quantity
Power loss
HYDRAULIC
PUMP
VXD70-1 F
!
Suction port
Section A-A
Detail of pump assembly
w
Section B-B
21, I
17
ii
/
18
Detail of servo valve
19
F23501077A
1. Servo
2. Pump
valve
assembly
3. Cylinder
4. Piston
5. Shoe
1O-82
0
assembly
block
6. Swash
plate
11. Coupling
16. Dummy
7. Front shaft
12. Housing
17. Yoke
8. Front cover
13. Swash
9. Housing
14. Rear shaft
19. Guide
15. Rear cover
20. Stopper
10. Center
section
plate
18. Servo
spool
piston
pin
PRINCIPLE
OF OPERATION
FUNCTION
.
It converts
the rotation
torque transmitted
pump shaft into hydraulic

pressurized
.
OF PISTON
energy,
oil corresponding
by the
and discharges
to the load.
It is possible to vary the amount

by changing
PUMP
of oil discharged
the angle of the swash plate.
OPERATION
Input shaft (2) is fitted with a spline and rotates
cylin-
der block
inside
(I ). The
the cylinder
distance
block
move
by the angle
in a reciprocal
of swash
plate
parts that
pump.
lever is at the Neutral

no movement
does
position,
when
by changing
When
control
plate is angled
rotates.
lever
continuous
and
(8)
is
is
speed
can be
angle
of the
the
is moved
through
the piston
rotation,
the
is discharged
to the
port
hole.
left,
B (71, and
through
motor
When
control
plate is angled
(I)
rotates.
sucked
(8) is moved
the
rotation,
is discharged
motor in the opposite
the
through
piston
to the
port
hole.
oil passes
to the
direction.
IS
is
out
port A
to rotate
the
right,
to the right and cylinder
Oil passes
in through
continuous
(71, and
lever
262F0
the
motor.
swash
I6
block
By carrying
oil passes
to the
262F0
lever.
to the left and cylinder
Oil passes
in through
there
so no rotation
The transmission
swash
sucked
the swash
the directional
and the sliding surface
of oil to the motor,
steplessly
only
and the cylinder
plate is flat and vertical,
to the motor.
This
(5). The
not contact
swash plate with the pump control
(6).
The
(3) of the pump.
Therefore,
of the pump swash
(I)
motion.
by trunnion
are the input shaft
input shaft
of the
controlled
plate
is supported
rotate
block. The
given
(4) contained
moved in and out by the pistons is controlled
swash
plate
nine pistons
motor
the
block
(61, and
By carrying
through
Input
Output
port
to rotate
is
out
B
the
Output
Input
262FO20
1 O-83
OPERATION
OF HYDRAULIC
PUMP
FUNCTION
l
This is a variable
piston
pump
amount
flow
displacement
with
servo
discharged
needed
which
to match
for the work
swash
plate
type
can
control
the
the pressure
equipment
and oil
and steering
circuit.
l
The
pump
servo
assembly
portion
consists
(servo valve
of the
and servo
pump
and
piston).
OPERATION
1.
When engine
l
piston
pressure
of spring
Swash
with
is generated,
(1) is pushed
force
l
is stopped
No hydraulic
fully
swash
left
by the
(2).
plate (3) of the pump
servo
so servo
to the
piston
is interconnected
(I), so it is at the maximum
plate angle.
235FO2024
2.
Immediately
control
1)
after engine starts (work equipment
lever, steering
The
pump
plate
angle,
charge
sent
and
port
at the
main
oil discharged
control
but the valves
ure in the circuit

This
circuit
chamber
valve
overcomes
(4) moves
spool
valve
chamber
(4)
P is
steering
so the press-
with
servo
valve
pressure
the force
that is
of spring
(5),
to the right.
moves
to
the
A and servo
are connected,
dis-
from
rises.
is connected
When
swash
from
and
are closed,
A, and the hydraulic
generated
so spool
maximum
oil is discharged
P. The
to the
valve,
not operated)
rotates
and servo
right,
piston
piston
servo
chamber
(1) is pushed
to the right.
In addition,
discharge
with
piston
servo
chamber
B is larger
C, so servo
spring
piston
plate
charge
amount
is a feedback
improve
is 0. (Servo
pressure
servo
of
of chamber
This pushes
where
piston
chamber.
back
the
chamber
disC
It is used to
and stabilize
piston,
in the circuit.)
the force
force
(3) to a position
the response
of the
pressure
1 O-84
(1) overcomes
to the right.
swash
C, but the area of
than the area of chamber
(2) and the pushing
C, and moves
ation
port P is also connected
chamber
regardless
the operof the
235FO2025
2) In the condition
in the
in Section
circuit
valve
drops,
is pushed
(4) of the
servo
back to the left by spring
and the oil in servo

through
I), if the pressure
spool
piston
chamber
chamber
E and
(5),
B passes
is drained
to
the
and
the
case.
The
pressure
force
removed,
left
by
plate
of
in chamber
pushing
servo
so servo
spring
oil
from
ing force
the
angle
to increase
pump.
The
and piston
to a position
(1) is moved
(2), and
the
(1) to the right
piston
(3) is changed
rises again,
B drops,
piston
where
of swash
the discharge
pump
(4) moves
it balances
of spring
is
to the
pressure
to the right
with
the push-
(5), and it then stays in this
position.
When
this happens,
the difference
pressure
is determined
(5), and
is approx.
other
words,
the
2.0 MPa
pump
swash
plate
started,
and provides
angle
immediately
after
in balance
by the force
of spring
(20 kg/cm2).
is at the
before
the
engine
the maximum
the
the swash
plate angle
to reduce
the discharge
engine
is
discharge
is started,
is immediately
amount
In
maximum
but
returned
to nearly
235FO2026
the
minimum.
3.
Work equipment
If the work
ated,
the
through
servo
pressure
(when
and steering
valve
valve
In this
way,
down,
the
the
work
the high
at spool
the
angle
As the amount
creases,
of
the
the circuit
valve
control
the
chamber
B goeS
(3)
becomes
increases.
from
circuit
the pump
rises.
the necessary
spool
pressure
enters
pressure
pressure
(4) to the right.

is balanced
at this
differential
point
by
In other
is bal-
pressure
of apPz sent
prox.
2.0 MPa (20 kg/cm2)
+ load pressure
from
the actuator
the LS line.
through
in-
When
port A of
2.0 MPa (20 kg/cm2).
control
valve
to the left. As a
plate
pressure
and pushes
pump
by the
in
amount
differential
absorp-
side to cham-
(1) moves
with
(5) at approx.
pressure
(4) of the servo
in the
is filled
control
at the same time,
of oil discharge
pressure
and oil flow,

the servo
equipment
swash
the actuator
words,
passes
D of the
to the left.
pressure
piston
and the discharge
spring
are oper-
actuator
pressure
(4) moves
and servo
result,
anced
of the
(6) inside the surge
sends
is lost and spool
The
operated
or steering
are operated
ber D). The balance
larger
levers
the LS line and goes to chamber
shuttle
tion
load
valve
lever
lever, steering
equipment
235FO2027
1 O-85
4.
When work equipment

When
the cylinder
the relief
pressure
valve
through
D of the servo
is balanced
pressure
approx.
2.0
pressure
P2 of the
pressure
is equal
are relieved
transmitted
is sent to chamber
The servo
and steering
reaches
by control
MPa
(20
differential
kg/cm2)
LS line. Therefore,
to the relief
the LS line
valve.
pressure
load
the
pump
+ approx.
2.0 MPa (20 kg/cm2).

The cylinder
the flow
plate
has reached
is kept
ure will
at the same
rise further.
further,
the balance
and the pressure

rise. This pushes
reduces
In other
words,
while
(minimization
angle,
If the
in servo
servo
at
the pump
pump
valve
piston
press-
pressure
rises
will be lost
chamber
B will
piston
(I) to the right
discharged
by the pump.
relief,
relief
the
the
discharge
of power
and
so if the swash
of the servo
the amount
maintained
duced
the end of its stroke
of the oil has stopped,
pressure
amount
is
and
is
re-
loss).
235FO2028
1O-86
8
4
8
PRIORITY FLOW DIVIDER VALVE
17.2MPa
235FO2029
1.
Relief valve
2.
Strainer
3.
Spool
4.
Body
5.
PLUG, damping
6.
PLUG, flow
7.
Orifice
8.
Spring
orifice
control
orifice
(for high response
actuation)
235FO2030
1 O-87
FUNCTION
l
When
the
hydraulic
equipment
pump,
and
if the
operated
work
time,
prevent
priority
and
the
one
are
is danger
that
may be insufthe steer-
dangerous,
to the steering
is maintained
work
by
steering
to operate
is extremely
this, the oil flow
given
and
circuit
it impossible
ing. This condition
both
covered
there
of oil to the steering

making
for
are
equipment
at the same
the flow
ficient,
systems
steering
so to
circuit
by this
is
priority
valve.
l
This valve
is a load sensing
the necessary
steering
tral,
flow
is operated.
if a large
circuit,
cuit
will
and
the
when
of oil to the steeering
equipment
cir-
efficiency
will
this and to ensure

is operated,
circuit
the steering
when
min),
and all the rest of the oil flows
equipment
circuit.
pressure
a different
for
the
function
relief
work
at neutral
(approx.
of the steering
pressure
from
equipment
of preventing
circuit
It also
abnormal
1 Q/
to the work
the relief
circuit.
any
quick
the flow
is kept to the mini-
mum
The relief
the
is at neu-
to the steering
operating
the steering
only
when
the steering
of oil flows
poor. To prevent
response
and ensures
of oil to the work
drop,
become
When
amount
the flow
type
of oil to the steering
is set as
pressure
has
pressure
the
in
the circuits.
OPERATION
1.
When engine
Spool
is stopped
(1) is pushed
In this condition,
to the right by spring

port
CF is opened
(2).
to the
maxi-
mum and port EF is closed.
235FO2031
1O-88
2.
When
engine
is started
(steering
and main con-
trol valves at neutral)

The oil from
the pump
but the steering

steering
circuit
The oil from

in spool
the pump
drained
to thetank
orifice
this flow
cm*)
time,
is formed
to the
sides
C + 1.0 MPa (10 kg/cm2),

(1).
the
becomes
passing
the
smaller,
through
to
pushed
oil
through
becomes
larger,
close.
the
larger.
the
opening
acting
at
When
the
at portion
This is repeated
The forces
until
PB [-
portion
in the drain
d
circuit
smaller,
sides
SO
spool
(1)
is
(2), and the flow
of
Spool
d
portion
oil
flow
again
becomes
d again
tries
to
is reached.
B and chamber
(converted
235FO2032
of orifice
pushing
a balance
on chamber
are as follows:
.
Force in left direction
force):
d of spool
weaker.
opening
b. The
(1) is pushed
and the force

by spring
a dif-
(IO kg/
in chamber
at
on both
becomes
to the right
of orifice
b becomes
pressure
left
lb,
1.0 MPa
portion
the oil flow
smaller
the
orifice
opening
orifice
differential
b becomes
(1)
of
is
(the
1 Urnin.)
so spool
to close
C,
and
valve
B is the pressure
to the left and tries

area
chamber
the steering
through
on both
spool
the oil passing
of approx.
in chamber
If the
in
orifice
LS circuit,
is normally
passes
in pressure
pressure
through
(1) enters
through
in the LS circuit
ference
valve,
so the pressure
B, and pushes
b of spool
from
When
passes
chamber
left. At the same
orifice
passes
flow
to the steering
is closed,
CF rises.
(I), enters
(1) to the
through
flows
valve
to hydraulic
1.6 MPa (16 kg/cm2)]
Force in right direction:

PC + 1 .O MPa (10 kg/cm)
[= 1.6 MPa (16 kg/cm2)]
[I.0
MPa
converted
(10 kg/cm2)
for spring
is the
hydraulic
force
(2)]
1 O-89
0
3.
Steering
operated
(main
control
valve
wheel
is turned,
at neu-
tral)
When
the
valve
is switched,
steering
connected
to
happens,
higher,
the
the
and
spring
and
port
steering
pressure
spool
the
CF and
cylinder.
(1) becomes
pump
passes
wheel
is being
goes from
larger,
through
port
turned,
to the
right
so the oil from
the
CF when
valve
by
of portion
the steering
and the necessary
the steering
this
C becomes
(2). The area of the opening
of spool
LS are
When
in chamber
(1) is pushed
steering
port
oil flow
to the steering
cylin-
der.
If the
steering
wheel
is turned
area of the variable

becomes
larger,
throttle
the
difference
both sides of the variable

ing valve
the
becomes
LS circuit
in
throttle
smaller,
rises.
quickly,
and
in the steering
pressure
inside
and the
(The pressure
the
valve
on
the steer-
pressure
in
in chamber
in chamber
drops)
At the same
also
rises,
right,
time,
(1) is moved
further
and the area of the opening
also becomes
the
the oil pressure
so.spool
steering
steering
larger.
This sends
cylinder.
On the
wheel
is turned
pressure
on both sides
side
steering
the
of portion
other
slowly,
hand,
the
becomes
pressure
in chamber
B becomes
pressure
in chamber
C, so spool
becomes
smaller
to match
valve.
if the
differential
throttle
larger,
in-
and the
larger
than
the
(1) is pushed
the left, and the area of the opening

for the steering
a large oil flow to
of the variable
valve
to the
of portion
the flow
It becomes
to
d
of oil needed
balanced
in this
position.
In other
words,
spool
(1) moves
in accordance
with the flow
of oil needed
for port CF to maintain
the differential
pressure
chamber
chamber
between
C at 1.0 MPa
(10 kg/cm2),
the opening
of portion
not needed
for the steering
and
Id. (In this way,
B and
adjusts
all the oil
can be used
at port
EF.)
When
the oil from
linder
and load is applied,
port
cuit rises. This signal

fed
back to the
the swash
plate
the discharge
feeds
1O-90
the
forms
valve.
back this information
the press-
the EL circuit
on
the
of
to increase
and to increase
load
and is
The angle
changed
cy-
in the cir-
the PLS circuit
servo
In this way,
hydraulic
the steering
the pressure
in the pump
amount,
ure in the circuit.

detect
pump
CF enters
steering
to the pump.
acts to
and
235FO2033
4.
Steering
When
cylinder
at end of stroke
the steering
stroke,
and
cylinder
the
reaches
operator
steering
wheel,
stopped
regardless
the end of its
continues
the flow
to
of oil to the
of the opening
turn
the
cylinder
is
of the steering
valve.
There
is no flow
of oil, so the CF and
ures rise together

P, and
at the
with
same
the pressure
time,
also rise, and spool

If pressure
PC goes above
relief valve
(3), which
by spring
pressures
(I) is moved
(4), opens
LS press-
at pump
port
PB and
PC
to the right.
17.2 MPa (175 kg/cm2),
is being
pushed
and drains
to the right
the oil in chamber
C.
Because
ure
of this flow
on both
pressure
spool
the
Spool
of the
spool
than
pressure
and
PB. As
to the left to a position
inside
the
spool
at a position
where
is throttled,
loss when
in press-
b is created,
lower
(1) moves
oil flow
(1) remains
large
of oil, a difference
of orifice
PC becomes
a result,
where
sides
and
is 1 Q/min.
portion
this
the oil is drained
prevents
the
if the circuit
235FO2034
is
relieved.
If spool
(1) moves
closed
through
orifice
pressure
moved
again
portion
d.
to the
same,
right
Because
of oil
PC
and
and spool
by spring
of this
d is
The flow
so pressure
the
in the steering
maximum
flowing.
b stops,
PB become
pressure
5.
too far to the left, portion
and the oil stops
is
(2) to open
repeated
circuit
(I)
action,
the
is maintained
at a
of 17.2 MPa (175 kg/cm2).
Steering
valve at neutral,
work
equipment
con-
trol lever operated

If the work
pressure
equipment
24.5 MPa (20 ing
valve
same
is at neutral,
main control
the
valve
spool
rises
flowing
A large difference
the
area
becomes
tion,
the
smaller
the oil flow
only 1 Q/min flows
and
the
oper-
of pressure
at port
amount
of
CF
oil
b increases.
right,
is created,
and
d becomes
opening
and
is the
(steering,
and the force
regardless
in pressure
to the
of portion
of
condition
is started
at neutral),
orifice
to 2.0 the steer-
PA rises, the pressure
through
opening
so the
momentarily,
(1) is pushed
are operated,
changes
However,
engine
(1) is constant
PA. If pressure
also
levers
port
250 kg/cm2).
as when
ating
control
PA of the pump
of
the
so spool
area
larger.
portion
is balanced.
is automatically
to the steering
of the
However,
d
In this
adjusted
again
condiso that
valve.
235FO2035
10-91
6.
Steering,
work
equipment
operated
simulta-
neously
1)
When
load
on steering
circuit
is higher
load on work
equipment
The actuation
condition
is basically
3 When
steering
as in Section
(main control
valve
the same
of spool
(I)
pressure
until
as pump
it balances
as the pressure
equipment.
pressure
63
A
is operated
A, and port EF is throttled
pressure
at neutral).
Port CF is at the same

chamber
than
circuit.
In other
at the same
needed
words,
for the pump
port
by portion
for the work
the
main
circuit
is sent to the steering
circuit.
To steering
cylinder
J
235FO2036
2)
When
load on steering
on work
equipment
circuit
is less than load
circuit
Circuit
CF
amount
of oil and oil pressure
circuit,
satisfies
but compared
pressure
through
at port
portion
the pressure
area
becomes
pressure
port
(I)
the
and
needed
less of the
(1) increases
moves
to the
at
oil flow
matches
the
words,
pressure
that
and
steering
in the
circuit
by priority
work
and
d
the
needs
the pressure
circuit
left,
portion
so
the
the
of oil
B rises.
balances
for
the
CF, when
the flow
It
plied to the steering
for
for the steering
port
opening
smaller.
CF. In other
flow
with
d of spool
spool
of
demand
EF is higher,
in chamber
As a result,
the
the
of
and oil
is supregard-
equipment
circuit.
235FO2037
1 O-92
SURGE PRESSURE ABSORBING
VALVE
B-B
A-A
235FO2038
1.
Cover
P.
From hydraulic
2.
Body
T.
To hydraulic
From hydraulic
3.
Spool
Xl.
4.
Valve
X3. From steering
5.
Shuttle
valve
6.
Shuttle
valve
plug
pump
tank
control
valve
R.H.
valve
L.H.
valve
X4.
From hydraulic
YI.
From servo valve
control
1o-93
FUNCTION
.
If the control
position
and
the
swash
control
plate
minimum
pump
there
lever
is moved
to neutral,
valve
plate
continues
is high
pressure).
pump
to the
by the inertia,
oil.
As
in the pump
valve
the
returning
discharge
pressure
This
the pump
but
from
angle
to
an operating
between
is closed,
is prevented
swash
from
the circuit
is installed
so the
a result,
circuit
(surge
to prevent
this
high pressure.
.
In order
to obtain
charged
ment
from
the necessary
the
or steering
detect
the
pump
highest
pressure
pendent
valves
(left,
valve),
and
of oil dis-
work
equip-
it is necessary
from
the three
right,
main
to send
this
to
inde-
control
valve,
information
to
of detecting
the
servo valve.
This valve
highest
the
are operated,
steering
the pump
amount
when
also
has the function
pressure.
OPERATION
I.
Control
lever or steering
If we take
of the
right
steering
control
valve
pressure
valve,
as PXI
PXI,
which
sent to chamber
The following
PXI
>
PX3
is the
>
PX4,
highest
shuttle
the pump
pressures
valve,
and
hydraulic
pressure,
valves
is
(3) and
discharge
press-
to port A.
forces
are acting
to right from
on spool
chamber
(1).
A:
+ 2.0 MPa (20 kg/cm*)
[2.0 MPa (20 kg/cm*)

ure
size of the
left control
B by two
(4). At the same time,

ure is connected
Pressure
operated
the comparative
of
the
pump
is the differential
control
pressure
pressfor
the
valve.]
Pressure
to left from
chamber
B:
PXI
i- 2.4 MPa (24 kg/cm2)
[2.4
MPa
draulic
(24
pressure
The pressure
kg/cm2)
for spring
in chamber
A.
is the
converted
hy-
(2)]
B is larger,
is at the left and closes the drain
so valve
(I)
port.
TO
priority flow 6
divider valve
235FO2039
1o-94
2.
When
operation
of control
lever
or steering
is
stopped
The moment
steering
and the valve

tia,
the
pump
mediately
the
pump
a result,
momentarily,
port
is closed.
swash
continues
B, valve
swash
pressure
or
of iner-
return
im-
plate angle,
and
oil, so there
to the
is
circuit.
chamber
it exceeds
(1) is moved
prevents
not
discharge
in
lever
the pump
because
does
to discharge
and when
leases the pressure

cuit and
between
However,
plate
in the pump
the
of the control
the circuit
to the minimum
high pressure
As
the operation
is stopped,
rises
the pressure
right.
in
This
re-
in chamber
A to the drain
cir-
the generation
of surge
press-
ure.
divider valve
235FO2040
1o-95
HYDRAULIC
HYDRAULIC CONTROL VALVE
CONTROL VALVE
Serial No.: 11001 - 12022

L.H. VALVE
(Left blade lift, Ripper, Blade side shift, Power tilt and Circle rotation)
12345
H - H, J - J
1-G
K-K,L-L
F-F
A-A
B-B
C-C.D--D
io
1. Blade lift spool
2. Ripper
(L.H.)
spool
3. Blade side shift spool

4. Power
tilt spool
5. Circle rotation
spool
6. Pilot relief valve

7. Shuttle
valve
8. Body
9. Pressure
compensating
10. Flow control
valve
P. From hydraulic
T. To hydraulic
E-E
235FO2041
1O-96
0
pump
tank
valve
R.H. VALVE
(Right blade lift, Leaning, Articulate,
Drawbar and Service)
G-G
l--G
H-H,J-J,
K-K
F-F
A-A,B-B,C-C
D-D
E-E
J
\
10
235FO2042
1. Drawbar
2. Articulate
shift spool
spool
3. Leaning
spool
4. Service
spool
5. Blade lift spool
(R.H.)
6. Pilot relief valve

7. Shuttle
valve
8. Body
9. Pressure
compensating
10. Flow control
P. From hydraulic
T. To hydraulic
valve
valve
pump
tank
1o-97
0
STRUCTURE
AND FUNCTION

L.H. VALVE
(Left blade lift, Ripper, Blade side shift, Power
A-A.
B-B
c-c.
D-D
HYDRAULIC
CONTROL
VALVE
tilt and Circle rotation)
E-E
H-H
G-G
10-97-l
0
SWG00366
1.
2.
3.
4.
5.
6.
7.
Blade lift spool (L.H.)

Ripper spool
Blade side shift spool
Power tilt spool
Circle rotation spool
Shuttle valve
P:
T:
From hydraulic pump

To hydraulic tank
valve spool
STRUCTURE
AND
FUNCTION
R.H. VALVE
(Right blade lift, Leaning,
HYDRAULIC
Articulate,
Drawbar
CONTROL
VALVE
shift and Service)
F-F
A-A,
c-c.
E-E
E-0
D-D
H-H
G-G
SWG00369
1.
2.
3.
4.
5.
6.
7.
Drawbar shift spool

Articulate spool
Leaning spool
Service spool
Blade lift spool (R.H.)
Shuttle valve
P:
T:
From hydraulic pump

To hydraulic tank
valve spool
10-97-2
0
PRESSURE COMPENSATING
MECHANISM
Serial
No.:
11001
The control
OF
- 12022
valve
acts to start,
accelerate,
decelerate,
and stop the actuators.

A feature
which
metering
function
trol flow
of the valve
lector
the
valve).
lever
disadvantage
when
the
in
pressure
To overcome
this problem,
constant
gardless
of the load
sating
either
to obtain
mechanism
by the
and
load
slow
side
press-
it is fast
when
the
the
control
control
flow
The pressure
is used to perform
the
to keep the
of
a constant
pressure.
by
it has the
it is necessary
on
(throttle)
valve
is the same,
is low
is high.
difference
of the se-
by controlling
However,
stroke
load pressure
pressure
stroke
selector
it is influenced
if the valve
load
the
is the
the con-
is obtained
is controlled.
that
ure, so even
functions
between
and the spool
feature
installed
the
of these
(the relationship
This
throttle
amount
is typical
re-
compen-
this function.
OPERATION
1.
Control
lever
at neutral
(immediately
after
en-
gine is started)
The oil discharged
ber B from
spool
(2), and
than the force

spool
When
pressure
right,
and
control
flow
the
equipment
spool
.cham-
C through
(3), so pressure
orifice
greater
compen-
to the right.
spool
A and chamber
0.6 MPa
the force
(2) moves
(6 kg/cm2),
of spring
to
B are closed,
which
(3), is supplied
B.
hydraulic
to
enters
compensation
C becomes
compensation
pressure
with
to chamber
The
chamber
(2) moves
chamber
balances
pump
in chamber
of spring
sation
the
A of pressure
enters
b. The pressure
the
from
chamber
pressure
from
work
equipment
circuit
is closed
the
pump
because
by work
does
the
not
work
equipment
(1).
235FO2043
1 O-98
0
2.
When
1)
control
If the
lever is operated.
control
equipment
lever
spool
from
the pump
ber
E of work
through
is
operated
(1) moves
enters
chamber
equipment
chamber
and
work
to the left, the oil

F from
spool
cham-
(I),
G, and is sent
passes
to the work
equipment.
The
pressure
spring
in chamber
chamber
applied
to the right
sation
spool
moves
pressure
to chamber
chamber
pressure
and is applied
pensation
passes through
in
spool
overcomes
chamber
(2), so the pressure

becomes
the
back
acting
of
the
pressure)
(3), pressure
to the
in cham-
right.
in
and when
pressure
the
compensation
on pressure
b
com-
rises, the force

greater,
sum
D (load
pushed
orifice
to the left end of pressure
the left direction
force
(2)
A is
B, and the pressure
ber C rises. As the pressure
spring
spool
chamber
B rises.
The pump
it
compenin cham-
compensation
circuit
to
a, and is
the pressure
to the left, pump
connected
orifice
end of pressure
(2). When
ber D rises,
G is transmitted
D through
spool
At this
in
force
235FO2044
(2) is
point,
compensation
of
the
spool
(2) is as follows.
Force in right direction
Force
In
in left
force
of spring
this
condition,
spool
= pump
direction
pressure
load
force
(3)
pressure
(2) is balanced,,so
compensation
the pressure
on the
left and right sides is equal.

Pump
pressure
spring
(3)
The differential
load
pressure
tion
H (chamber
trols
the flow
pressure
of spring
and
force
of
on both sides of por-
F, chamber
of oil for work
(1) is determined
force
kept
(3) (approx.
G), which
con-
equipment
spool
constant
by the
0.6 MPa
(6 kg/
cm2)).
1o-99
2)
When
the
pressure
for
the
rises,
the
pressure
in
chamber
chamber
D through
ance
at pressure
lost.
Pressure
pushed
J
at the
left and
bypass
ber B and flows
spool
end,
to chamber
(2)
control
so the
chamber
bal(2) is
spool
opens
to
and the
is
corner
oil from
the
A through
cham-
G of work
equip-
(1).
pressure
pump
a,
compensation
passes from
ment spool
The
orifice
equipment
G goes
compensation
to the
pump
work
in
pressure
chamber
rises,
and the pressure
so
the
in chamber
B also rise.
The pressure
in chamber
ber C through
pensation
spool
right,
and
pressure
again
becomes
ference
force
the
goes
down,
sides
com-
back
compensation
The
of flow
F, chamber
to
the
spool
(2)
pressure
control
dif-
portion
G) is taken
as the
(3).
235FO2045
pressure
to chamber
to cham-
so pressure
balanced.
of spring
When
B passes
b,
(2) is pushed
on both
H (chamber
3)
orifice
in the
the pressure
D through
ance
at pressure
lost.
Pressure
work
to
the
through
control
right
and
corner
G goes
a, and the bal-
orifice
compensation
spool
compensation
pushed
equipment
in chamber
spool
the
flow
C
\\\\
J
Lv/
(2) is
(2)
is
of
oil
at the bypass
end
is reduced.
Because
of this,
and chamber
pensation
and
becomes
pressure
trol
spool
pressure
in chamber
so pressure
(2) is pushed
At
difference
H
the force
In this way,
pressure
compensation
balanced.
portion
becomes
the
C goes down,
back to the left

spool
the
point
the
on both sides of flow
con-
(chamber
F,
of spring
pressure
chamber
AP
difference
control
portion
stant
[approx.
0.6 MPa (6 kg/cm2)],
S of the opening
of flow
constant,
Q which
constant
0 m (proportional)
10-100
S X JZF
on both
H is kept
control
regardless
G)
(3).
of flow
remains
(2) again
where
sides
oil flow
com-
passes
con-
se if area
portion
through
of the load.
H is
it
235FO2046

OPERATION
1. Control lever at neutral (immediately
after
engine is started)
The oil discharged
from the pump enters
chamber
B from chamber A. The pressure in
chamber
C becomes
greater than the force
of spring (3), so pressure compensation
spool
(2) moves to the right.
When
pressure
compensation
spool
(2)
moves to the right, chamber A and chamber
B are closed, and control
pressure,
which
balances with the force of spring (31, is supplied to chamber
B.
The hydraulic
pressure form the pump does
not flow to the work equipment
because the
work equipment
circuit
is closed by work
equipment
spool (I ).
The control valve acts to start, accelerate,

decelerate, and stop actuators.
A feature which is typical of these functions
is
the metering
function
(the relationship
between
the control flow of the valve and the spool stroke
of the selector
valve). This feature
is obtained
by controlling
the throttle
installed
in the selector valve by the amount the lever is controlled.
However,
it has the disadvantage
that it is the
influenced
by the load pressure,
so even if the
valve stroke is the same, it is fast when the load
pressure
is low and slow when the load pressure is high.
To overcome
this problem,
it is necessary
to
keep the pressure
difference
on either side of
the control
(throttle)
constant
to obtain a constant control
flow regardless
of the load pressure. The pressure compensating
mechanism
is
used to perform
this function.
SWG00428
10-100-1
0
2.
When work equipment

lever is operated
1) When
work equipment
spool (1) is
moved up, the oil in chamber B passes
through chamber C of work equipment
spool (1) and is sent to the actuator.
At the same time, the pressure in chamber C is transmitted from small hole a to
spring chamber D and is applied to the
right side of pressure
compensation
spool (2).
When the pressure in chamber D rises,
spool (2) moves to the left. Pump circuit
chamber A is connected to chamber B,
and the pressure in chamber B rises. The
pressure in chamber B is applied to the
left end of pressure compensation
spool
(2), so as the pressure in chamber B rises,
and the force to the right increases. When
it overcomes the combined force of the
pressure in chamber D (load pressure) +
force of spring (31, spool (2) moves to
the right. When this happens, the force
acting on pressure compensation
spool
(2) is as follows:
1o- 100-2
0
Pressure pushing to right = pump pressure

The force pushing to the left = load pressure + force of spring (31, so pressure
compensation
spool (2) is kept in balance in this condition.
The forces to the left and right are equal.
Pump pressure = load pressure + force
of spring (31, so the difference in pressure at the front and rear sides of the
flow control portion of work equipment
spool (I) (chamber B and chamber C) is
determined by the force of spring (3) and
is kept constant.
2)
When the pressure

for the work equipment rises, the pressure
in chamber
C
goes to chamber
D through
orifice a,
and the balance at pressure compensation spool (2) is lost. Pressure compensation spool (2) is pushed to the left and
opens control
corner E at the bypass
end, so the oil from the pump passes
from chamber A through
chamber
B and
flows to chamber
C of work equipment
spool (I).
The pressure in chamber
C rises, so the
pump
puressure
and the pressure
in
chamber
B also rise.
The pressure in chamber
B pushes back
pressure
compensation
spool (2) to the
right, and pressure compensation
spool
(2) again becomes
balanced.
The pressure difference
on both sides of flow
control
portion
(chamber
B, chamber
C)
is taken as the force of spring (3).
3)
When the pressure

in the work equipment goes down, the pressure in chamber C goes to chamber
D through
orifice
a I, and the balance
at pressure
compensation
spool (2) is lost. Pressure compensation
spool (2) is pushed to the right
and flow of oil through
control
corner
E at the bypass end is reduced.
Because of this, pressure
in chamber
B
and chamber
C goes down, so pressure
compensation
spool (2) is pushed back
to the left and pressure
compensation
spool (2) again becomes
balanced.
At
the point where the pressure difference
on both sides of flow control
portion
(chamber
B, chamber
C) becomes
the
force of spring (3).
In this way, pressure differnce AP on both
sides of flow control portion is kept constant, so if area S of the opening
of flow
control
portion
is constant,
oil flow Q
which
passes through
it remains
constant regardless
of the load.
QOC (proprotional)
S X liAP
SWG00429
1o- 100-3
0
BLADE LIFT SPEED ADJUSTMENT
MECHANISM
Serial No.: 11001 - 12022
OUTLINE
.
If there
is a great difference
on the left and right,

the
left
adjust
l
and
with
right
4.8 turns,
blade
speeds,
the adjustment
The adjustment
bolt
in the blade
or if it is desired
it is possible
speed
to
bolt.
has an adjustment
and if the adjustment
the cylinder
lift speed
to reduce
will become
bolt
range
of
is loosened,
slower.
FUNCTION
l
When
adjustment
spring
(3) is reduced,
bolt (1) is loosened,

so the force
the force
of
in the left direc-
tion is also reduced.

.
In this
both
condition,
sides
control
chamber
G) is reduced
trol spool
(2).
Therefore,
trol
On
oil flow
portion
der speed
l
the differential
of flow
the
screwed
the blade
Q passing
becomes
lift cylinder
Q CC (proportional)
(S = Area of opening
through
pressure
oil flow
and the blade
F,
concon-
lift cylin-
slower.
hand,
in, oil flow
on
AP
H (chamber
to balance
H is reduced,
other
pressure
portion
if
adjustment
Q increases,
becomes
(1)
is
and the speed
bolt
of
faster.
S X p
at portion
H)
235FO2047
1o- 100-4
0
Serial
No.: 12023 and up
Outline
.
If there is a great difference in the blade lift
speed on the left and right, or if it is desired
to reduce the left and right blade speeds, it
is possible to adjust with adjustment
bolt
.
(I).
If adjustment
bolt (I) is loosened,
der speed will become slower.
the cylin-
Operation
.
When adjustment
bolt (I) is loosened, the
force of spring (3) is reduced, so the force in
the left direction is also reduced.
In this condition, the differential pressure AP
on the front and rear sides of flow control
portion F (chamber B and chamber C) is reduced to balance pressure compensation
spool (2). Therefore,
the oil flow passing
through oil flow control portion F is reduced,
and the blade lift cylinder speed becomes
slower. On the other hand, if adjustment bolt
(I) is screwed in, oil flow Q increases, and
the speed of the blade lift cylinder becomes
faster.
QOC (proprotional)
S X m
(S = Area of opening at portion F)
SWG00431
PILOT CHECK
(For
Blade
lift
VALVE
R.H.)
1.
Pilot valve
2.
Check
valve
F23501093
F23501092
OPERATION
When
the
control
blade,
pressure
blade
lift
throttle
cylinder.
and
check
valve
(2),
head
pressure
This
pushes
valve
cylinder
and
When
the
on the
it pushes
in chamber
C suddenly
at the bottom
this
valve,
the check
cording
and
prevent
ends.
this,
a damper,
This
a throttle
so even
the check
The
escapes
blade
hold
lift
(21, the oil
to chamber
A, and
drops.
is no throttle
will always
cause
is installed
if the pressure
at the pilot
open and close ac-
in the pressure
will
valve
a
pilot
C at the
blade
end of the
check
the
through
opens
in chamber
tank.
head
if there
valve
to the changes
head
drops,
happens,
lower
end of the
passes
(1). This
oil
the
open
the pressure
When
valve
to
to
at the bottom
pressure
pilot
returns
is acting
cylinder.
is operated
is generated
blade
at the bottom
chattering.
at E which
To
acts as
at the bottom
end
valve will not close immediately.
I
1o-1 02
F23501094
PILOT CHECK VALVE

(For Articulate,
Leaning
and
Drawbar)
,5
1.
2.
3.
4.
5.
6.
Check valve
Piston
Body
Plug
Plug
Check valve
Al
_
A2
-
F23BH1115
F23BH1116
OPERATION
When the control valve is operated, the oil from the
pump enters port A,, opens check valve (61, and
flows into port B,. When a pressure is generated, the
oil from orifice E pushes up piston (2) and opens
check valve (1). so the oil connecting port B, and
port A, flows into the drain port.
Hunting occurs because check valve (1) opens and
closes in accordance with the fluctuations in pressure
at the bottom side and head side, but because of orifice E, a damper effect is provided so that check
valve (1) will not close immediately even if the pressure at port A, goes down.
F23BH1117
10-103
PILOT CHECK VALVE
(WITH
SAFETY
VALVE)
(For Blade lift L.H.)
1.
Check valve
2.
Plug
3.
Body
4.
Piston
5.
Relief valve
.-.
----.-.
R
'-1
F23501098
I-
A2
The check valve with safety

drift
of the
cylinder
from abnormal
When
pressure caused
hydraulic
the
by external
stopper
is shifted
valve
installed
(left) acts to prevent
F23501099
position
to the side, the drawbar
and lifter come into contact.
safety
cylinder
force.
the blade lift is raised to the maximum
and the drawbar

with
valve prevents
and also protects
Al
The check valve
to the blade
damage
lift cylinder
to the work equipment
caused by this contact.

OPERATION
When
the lever is operated
to retract
from the pump enters chamber

valve
(1).
flows
to the chamber
push
the
bottom
passes
cylinder
end
chamber
When
It then
through
chamber
BI
back
oil
and
at the head of the cylinder
piston.
flows
the cylinder,
AI and pushes check
The
oil at
through
the
chamber
to
cylinder
Bz and
AZ and returns to the tank.
the
lever
the oil from

through
is operated
the pump
chamber
the pressure
to extend
enters chamber
B2 to the cylinder
in chambers
the cylinder,
A2 and flows
bottom
end. As
A2 and B2 rises, piston
(4)
is pushed. This pushes open check valve (I ), and the

oil at
the
through
cylinder
the throttle
from chamber
If there
head
an abnormal
from
chamber
BI
AI hack to the tank.
is any shock
operations,
flows
of check valve (1). It then flows

to the work
and the pressure

pressure
of 280
equipment
in chamber
kg/cm2
during
BI rises to
or more,
relief
valve (5) is pushed open and the oil flows to chamber

B2. This raises the work
shock.
10-104
equipment
and relieves
the
235F247
(For Ripper and Power tilt)
1.
Check
2.
Piston
3.
Body
valve
4.
Check
5.
Relief valve
valve
-5
The check
valve
drift
of
the
from
abnormal
with
cylinder
safety
and
pressure
valve
also
prevents
protects
caused
hydraulic
the
by external
cylinder
force.
OPERATION
When
the lever
from
the pump
(2) and check
is.operated
enters
valve
ber B, and flows

of
the
back
cylinder.
through
returns
When
the
the
pushes
to the cylinder
shock
kg/cm2
passes
oil at the
chamber
the lever is operated

pump
sure in chamber
If
(4). It then
to the chamber
The
the cylinder,
A, and pushes
through
cham-
at the bottom
cylinder
head
B, and chamber
oil
piston
end
flows
A, and
to the tank.
oil from
This
to extend
chamber
A,
open
in chamber
and oil flows
check
valve
A,.
valve
(I),
chamber
abnormal
As the
(I)
the
pres-
is pushed.
and the oil flows

B,.
pressure
B,, it pushes
to chamber
the cylinder,
chamber
rises,
check
head from
causes
to retract
enters
open
B, to relieve
of
over
relief ,valve
280
(5)
the shock.
10-105
0
CIRCLE
ROTATION
MOTOR
Serial No.: 11001 - 12050

ME300-FTS
F23501104
1. Cover
2. Bearing
3. Thrust plate
4. Slipper
retaining
ring
5. Slipper
6. Spring
7. Piston
8. Bearing
9. Thrust
10. Timing
1 1. Cylinder
12. Shaft
13. Casing
ircle rotation
Circle rotatiol;
lo-106
0
motor
gear
F23501071-1
retainer
plate
block
plate
When
high
passes
pressure
through
oil flows
timing
plate
(1 1). This high pressure

movement
slipper
force
(5) to push
is generated
rotating
which
of the piston
force
forms
in from
(10)
oil acts on piston
thrust
retainer
in cylinder
is transmitted
plate
block
to
R, it
cylinder
(7). and the
in the axial direction
one unit with cylinder
causes
(9). Rotating
(1 11, and
output
shaft
the
(I 2),
block (1 1). When
the output shaft rotates
of the arrow
interconnected
main port
and enters
this happens,
oil after
F23501105
in the direction
, and even at low speed, performs

operation
actuating
passes
smoothly.
through
The low pressure

timing
plate
(IO)
and flows out from main port L.

If the inlet and outlet ports are reversed,
of rotation
the direction
is also reversed.
1o-1 07

ME150203AAAA
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
Housing
Key
Coupling
shaft
Drive shaft
Wear plate
Rotor set
Manifold
Commutator
ring
Commutator
End cover
lo-108
0
BLADE ACCUMULATOR
SYSTEM
235FO2048
Iii
----
1.
Solenoid
valve
(for blade float)
2.
Solenoid
valve
(for accumulator)
3.
Pilot check valve
4.
Accumulator
5.
Blade lift cylinder
6.
Blade lift control
valve
235FO2049
10-109
0
ACCUMULATOR
1.
2.
3.
4.
5.
6.
Cap
Shell
Bladder
Valve
Plug
Slow return valve
A:
B:
C:
Nitrogen gas
Pressure oil (from blade cylinder)
From solenoid valve
t
C
SWG00004
FUNCTION
When oil pressure is applied to the blade cylinder, the pressure oil flows to the accumulator
through the solenoid valve and pushes valve
(6). This pushes valve (4), and the oil flows into
shell (2). Thereby, bladder (3) is compressed.
Consequently,
the shock imposed on the blade
cylinder is reduced by the compressible
amount
of the bladder. When the oil pressure in the
blade cylinder drops, the bladder expands by
the gas pressure in bladder (31, and the oil in
10-110
0
shell (2) sends to the blade cylinder until the oil

pressure in the shell balances to that in blade
cylinder circuit. At this time, valve (5) closes
throttling the return oil. This prevents the oil in
shell (2) from flowing out abruptly and prevents
the bladder from striking against the inside of
the shell.
The flow of oil in the accumulator
hydraulic circuit is repeated smoothly to reduce the shock
imposed on the blade.
BLADE FLOAT SYSTEM
235FO2050
OUTLINE
l
When
the blade
blade float
(1) is actuated,
blade
l
is at the N position,
(6) is turned
ON, solenoid
and the bottom
lift cylinder
to the
circuit.
This sets the blade in a floating

blade
lift lever
float
switch
is operated
switch
condition.
to the RAISE or LOWER posi-
(5) turns
blade
returns
condition,
and this condition
float
to the normal
lift lever
switch
(6), and
RAISE or LOWER
is maintained.
is returned
the blade is placed
in a floating
If the
blade
switch
blade
raised,
float
of
drain
(6) is ON, and the blade
the blade
If the blade
and
valve
and head ends
(3) are connected
When
tions,
lift lever
switch
to the N position,
condition.
is turned
the blade will suddenly
ON with
the
drop.
235FO2051
1.
Blade float solenoid
2.
Pilot check valve
3.
Blade lift cylinder
4.
Blade lift control
5.
Switch
6.
Blade float switch
valve
valve
10-111
0
STRUCTURE
AND
FUNCTION
DRAWBAR
AND
DRAWBAR AND LIFTER

Serial No.: 11001 - 12050
==v
==- -==
-_==
__--
235CD02018
OUTLINE
The
drawbar
is
an
important
which
supports
the circle
worn,
use shim
(5) to adjust
so that there
clearance
(II),
adjust
bolt (9).
10-112
0
and blade.
is no excessive
at the
with
contact
shims
piece
of
If ball joint
the clearance
play. When
portions
(7) and
equipment
at the joint
and
Circle
Drawbar
3.
Blade lift cylinder
4.
Drawbar
the
5.
Shim
(8) and
6.
Ball joint
adjusting
of guides
(IO),
(6) is
1.
2.
adjustment
side shift cylinder
LIFTER
DRAWBAR
FUNCTION
AND
STRUCTURE
LIFTER
D-D
i2
ii
c-c
B-B
A-A
AND
114
G-G
F-F
235CD02019
There
ing
the
the
by
frame.
They
insertion
from
revolution.
pin stopping
the blade to make
holes
the operators
altogether
times,
These
(a) get used much
for the
7. Shim
8. Guide
9. Adjustment
11. Guide
12. Bolt
13. Yoke
At other
14. Lifter
bracket
(Upper)
bracket
(Lower)
15. Shim
more than other
holes and a
16. Lifter
bushing
tween
be(18) is used in it to make the clearance

(This clearthe pin and the hole at a minimum.
of the
the up and down movement
amplifies
17. Pin
18. Bushing
and
20. Pin
ance
blade.)
Also,
the guide
shims
force
the
welded
clearance
between
to the frame
(15). Pin (20) combined

prevents
bracket
bolt
10. Shim
Holes (b) and (c) are used for
a bank cut to left or right.
holes (a) are used.
in-
main
the
the guide
by revolving
a pin (17) controlled

are two
for mov-
(16) are
to
is welded
can be revolved
by extracting
seat. There
which
guide
in the lifter
(14) and
Brackets
device.
blade
stalled
installed
cylinders
are two
the
bracket
can be adjusted
with
up and down
19. Bolt
with
bolt (19) tightening

slippage.
10-113
0
STRUCTURE
AND
DRAWBAR
FUNCTION
OUTLINE
is an
The drawbar
ment which supports
joint (6) is worn, use
ance at the joint so
piece of equipimportant
the circle and blade. If ball
shim (5) to adjust the clearthat there is no excessive
play.
When adjusting the clearance at the contact portions of guides (20) and (17), adjust with shims
bolt (15).
(16) and (191, and adjustment
10-113-l
0
1.
2.
3.
4.
5.
6.
Circle
Drawbar
Blade lift cylinder
Drawbar side shift cylinder
Shim
Ball joint
AND
LIFTER
DRAWBAR AND LIFTER
B-B
I8
17
There are two cylinders installed in the lifter for

moving the blade device. Brackets (7) and (9)
are installed by the guide which is welded to
the main frame. They can be revolved by revolving the guide by extracting a pin (13) controlled from the operators seat. There are two
insertion holes altogether for the pin stopping
revolution. Holes b and c are used for the blade
to make a bank cut to left or right. At other
times, holes a are used.
These a get use much more than other holes
and bushing (14) is used in it to make the clearance between the pin and the hole at a minimum. (This clearance amplifies the up and down
movement
of the blade.) Also, the clearance
between the bracket and the guide welded to
the frame can be adjusted with shims (8). Pin
(12) combined
with bolt (11) tightening
force
prevents bracket up and down slippage.
G-G
F-F
SWG00376
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Lifter bracket (Upper)

Shim
Lifter bracket (Lower)
Yoke
Bolt
Pin
Pin
Bushing
Adjustment
bolt
Shim
Guide
Bolt
Shim
Guide
10-113-Z
0
STRUCTURE
AND
BLADE
FUNCTION
BLADE
Serial No.: 11001 - 12050
\
6
1
Y
235CO02020
FUNCTION
1. Bracket
Side edge (5) installed
to the blade
2. Blade shift cylinder
it can
by turning
be used
moving
it to the other
A power
angle
tween
tilt
device
is designed
so that
it upside-down
and
is installed
the
cutting
can be made freely
25 and 84 using a single

acts as a bushing
to adjust
be-
parts when
the blade to the side. If the clearance
from
sliding
parts
accuracy
cannot
be obtained,
10-l 13-3
0
is too
large
replace
and
the
finishing
the guide.
5. End bit
6. Bolt
7. Nut
lever.
for the sliding
3. Support
4. Blade
(left or right) side.
of the blade. Adjustment
The guide
shifting
twice
the
8. Cutting
9. Adjuster
10. Shaft
edge
BLADE
Serial
No.: 12051 and up
FUNCTION
Side edge (5) installed to the blade is designed
so that it can used twice by turning it upsidedown and moving it to the other (left or right)
side.
A power tilt device is installed to adjust the cutting angle of the blade. Adjustment can be made
freely between 25 and 84 using a single lever.
The guide acts as a bushing for the sliding parts
when shifting the blade to the side. If the clearance from the sliding parts is too large and the
finishing accuracy cannot be obtained, replace
the guide.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bracket
support
Blade
Side edge
Bolt
Nut
Cutting edge
Adjuster
Shaft
10-113-4
0
LIFTER BRACKET CONTROL PIPING
235CD02021
Detail A
F23501114
The lifter bracket
is fixed
bank cutting
position,
compressed
air to
removed
10-114
by pin (3). When setting in the

control lever. This uses
2.
Bank-lock
be
3.
Pin
operate
push
and the bracket
piston
(4). The
pin
can then be rotated.
can
1.
Air tube
4.
Piston
5.
Spring
6.
Bushing
valve
CIRCLE ROTATION
Serial
GEAR,
No.: 11001 - 12050
Circle rotation
motor
li
16
13
14
13
F23501400
1. Cover
Outline
The
circle
rotation
connected
When
to worm
the
plate
force
control
is driven
gear shaft
control
(15) are
motive
gear
valve
separated
is not
to pinion
operated,
disc
by spring
a brake.
gear
has
from
Pinion
an
the
abnormal
blade,
disc
(9)
motor
disc
(14)
and
oil, and
the
5. Shaft
gear
(9). If the
6. Case
(14)
and
7. Worm
(13) and
a clutch
rotating
force
(3) slips
to
plate
act as
mechanism,
is
prevent
transmitted
breakage
justed
clutch
4. Plate
wheel
8. Plug
9. Pinion
gear
10. Shim
11. Nut
12. Bolt
of the blade.
The
2. Spring
3. Disc
is operated,
together
if
oil
(17).
(15) are pressed

and
an
by pressurized
is transmitted
valve
by
pressure
by the thickness
of this
clutch
of shim (IO).
mechanism
is ad-
13. Spring
14. Disc
15. Plate
16. Drain plug
17. Worm
gear shaft
10-115
0
Outline
The circle rotation gear is driven by an oil motor
connected to worm gear shaft (13).
Pinion gear shaft (2) has a clutch mechanism,
and if an abnormal rotating force is transmitted
from the blade, disc (6) slips to prevent breakage of the blade.
The clutch pressure of this clutch mechanism is
adjusted by the thickness of shim (IO).
lo-116
0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Flowting seal
Shaft
Case
Worm wheel
Plate
Disc
Plug
Spring
Cover
Shim
Pinion gear
Drain plug
Worm gear shaft
Oil motor
REAR MOUNT
RIPPER
III
-7
Section A-A
Section B-B
Section E-E
Section C-C
Ripper
lifting
trolled
with
height
ripper
cut into the

digging
Two
work
kinds
and digging
cylinder
ground
heavy weight,
Section D-D
under
depth
(1). Since
the
can be conthe
load of the rippers
the ripper easily performs

which
of points
point for heavy-duty
cannot
heavy-duty
be done by the scarifier.
are selectively
work
point tips
used:
A short
Section G-G
Section F-F
F23501118
Ripper cylinder
2.
Pin
3.
Bracket
4.
Shank pin
5.
Shank
6.
Point
and a long point for ordi-
nary work.
10-l 17
0
CONTROL LINKAGE
HYDRAULIC
1234
10
235FO2052
wheel
Steering
panel tilting
and instrument
mech-
anism:
Rotate
suitable
angle can be adjusted
Console
box tilting
Depress
pedal
the console
In this way,
steplessly
wheel
position
lever
20.
pin, and
for the operator.
box
lever
tilt lever
8. Blade shift lever
in five stages.
and console
7. Power
can
9. Ripper
lever
10. Blade lift L.H. lever

11. Tilt lever
12. Pedal
lo-118
0
lever
shift lever
5. Drawbar
6. Circle rotation
the dowel
box can be adjusted
the steering
lever
3. Leaning
4. Articulate
mechanism:
(12) to remove
be set to the optimum
to a
the lever.
then tighten
position,
The tilting
l
the lock, move
(11) to loosen
tilt lever
1. Blade lift R.H. lever

2. Service
A-A
B-B
F-F
E-E
G-G
H-H
235FO2053
10-119
0
023502
Serial No.: 11001 12502
10-120
(6)
023502
1.
2.
3.
4.
5.
Main frame
Articulate cylinder
Center pin
Pin
Grease fitting
10-120-1
(6)
AIR CONDITIONER
023502
Serial No.: 11001 11013
10-120-2
(6)
AIR CONDITIONER
023502
10-120-3
(6)
AIR CONDITIONER
MOUNT-ON CONDENSER OPERATOR CAB SPECIFICATION
023502
AIR CONDITIONER PIPING

SYSTEM DIAGRAM
1.
2.
3.
4.
5.
6.
7.
10-120-4
(6)
Air conditioner unit

Receiver tank
Compressor
Condenser
Hot water heater
Evaporator
Blower unit
ELECTRICAL WIRING DIAGRAM
023502
(1/3)
1.
2.
3.
4.
5.
Head lamp
Front combination lamp
Front working lamp (front of blade)
Front working lamp (rear of blade)
Parking brake valve
6.
7.
8.
9.
10.
Air horn valve

Battery
Radiator coolant level sensor
Battery relay
Transmission solenoid valve pick-up
10-121
(6)
023502
(2/3)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Heater relay
Fuel gauge pick-up
Ground connection of engine
Final drive oil temperature sensor
Rear combination lamp
Rear working lamp
Back-up lamp
Back-up alarm
Differential lock valve
10-122
(6)
10.
11.
12.
13.
14.
15.
16.
17.
18.
Air pressure sensor

Hydraulic oil temperature sensor
Hydraulic oil level sensor
Air gauge sensor
Engine oil level sensor
Engine oil pressure sensor
Speed sensor
Water temperature gauge pick-up
Coolant level sensor (if equipped)
(3/3)
023502
Serial No.: 11001 12502
10-123
(6)
(3/3)
023502
1.
2.
3.
4.
5.
6.
7.
8.
Cluster gauge and pilot lamp

Turn signal lamp switch
Monitor panel
Fuse box 1
Fuse box 2
Stop lamp switch
Hazard relay
Flasher relay
10-123-1
(6)
9.
10.
11.
12.
13.
14.
15.
Horn relay
Emergency steering relay
Engine stop motor relay
Emergency steering controller
Warning buzzer (for emergency steering)
Engine oil pressure relay
Warning buzzer
Serial No.: 12013 - 12015, 12019 and up
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
R switch
F switch
Caution lamp
Potentiometer
(for shift lever)
Alarm buzzer
Relay (for alarm buzzer)
Transmission
controller
Engine speed sensor
Potentiometer
(for inching)
Transmission
oil temperature
sensor
(transmission
outlet port)
11. Transmission
solenoid
12. Speed sensor
lo-124
0
This shows components

that have been
added because of the installation of the transmission controller.
MONITOR
PANEL, CLUSTER GAUGE AND PILOT LAMP
Serial No.: 11001 - 11030
27
235CD0202B
23
1. Coolant
temperature
2. Caution
monitor
15. Front wiper
gauge
16. Service
group
17. Front wiper
3. Speedometer
4. Accumulator,
5. Service
blade float select switch

control
switch
7. Differential
control
indicator
8. Accumulator
10. Parking
11. Warning
18. Rear wiper
indicator
indicator
lamp
lamp
blake indicator
lamp
lamp
lamp
switch
(Lower)
gauge
20. Door wiper
switch
21. Emergency
steering
select switch
22. Lift arm lock indicator
lamp
23. Bank cut switch

24. Cab head lamp switch
25. Rear working
lamp switch
12. Head lamp switch
26. Front working
13. Fuel gauge
27. Starting
switch
14. Dimmer
28. Parking
brake switch
switch
(Upper)
switch
19. Air pressure
meter
6. Differential
9. Blade float
switch
meter
lamp switch
10-125
0
,22
23
27
26
1. Coolant temperature
gauge
2. Caution monitor group
3. Speedometer
blade float select switch
4. Accumulator,
5. Service meter
6. Differential control switch
7. Differential control indicator lamp
8. Accumulator
indicator lamp
9. Blade float indicator lamp
10. Parking brake indicator lamp
11. Warning lamp
12. Head lamp switch
13. Fuel gauge
14. Dimmer switch
15. Front wiper switch (Upper)
10-126
0
25
24
SDG00009
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Service meter
Front wiper switch (Lower)
Rear wiper switch
Air pressure gauge
Door wiper switch
Emergency steering select switch
Lift arm lock indicator lamp
Bank cut switch
Cab head lamp switch
Rear working lamp switch
Front working lamp switch (rear of blade)
Front working lamp switch (front of blade)
Starting switch
Hazard switch
(1/2)
023502
Serial No.: 12013 12015, 12019 12098
10-134
4
(2/2)
023502
Serial No.: 12013 12015, 12019 12098
10-135
4
(1/2)
023502
Serial No.: 12099 12502
10-136
(6)
(2/2)
023502
Serial No.: 12099 12502
10-136-1
(6)
STRUCTURE
TRANSMISSION
AND FUNCTION
ELECTRICAL
ELECTRICAL
CIRCUIT
DIAGRAM
CIRCUIT
Serial No.: 11001 - 11030
CN-TO1
Rotary
Diode
______
I Transmission
solenoid
valve
SWG00437
10-137
0
STRUCTURE
AND
FUNCTION
Serial No.: 11031 - 12012,
ELECTRICAL
CIRCUIT
DIAGRAM
12016 - 12018
CN-RPB
Relay
(parking
brake1
iJJ
Diode
SWG00438
lo-138
0
STRUCTURE
AND
FUNCTION
ELECTRICAL
FR
detect
Caution
CIRCUIT
buzzer
DIAGRAM
Cautlan
buzzer
CN-RDI
yifferential
ock relay
lamp
used)
Shift
potentic
meter
Shift
Potentlo
meter
Inching
CN_TM,,
#-
Potentio
mete
,.___________
SWG00440
023502
Serial No.: 12099 12502
10-141-2
(6)
ELECTRICAL CIRCUIT DIAGRAM
023502
Serial No.: 12001 12502
10-142-1
(6)
EELCTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

(Refrigerant for R-12)
023502
Serial No.: 11001 11013
10-143
(6)
(Refrigerant for R134a)
023502
Serial No.: 11014 12502
10-144
(6)
r-k
CN-A6
CN-A3
If--!
Damper
Air
conditioner
unit
ComPressor
4
I
CN-27
Pressure
II
From
Lisnt
Fuse
switch
box
CN-
SWG00443
10-145
0
ELECTRICAL CIRCUIT DIAGRAM (1/6)
023502
10-146-1
(6)
023502
10-146-3
(6)
023502
10-146-5
(6)
023502
(Transmission)
10-146-7
(6)
023502
(Steel cab)
10-146-9
(6)
023502
(Air conditioner)
10-146-11
(6)
ELECTRONIC VEHICLE MONITORING
SYSTEM (EVMS)
SYSTEM (EVMS)
Serial No.: 11001 - 12000
-4A
2A
5A
5c
ii
1.
2.
IA.
Coolant
IB.
Fuel level
2A. Hydraulic
5B. Emergency
starting
items)
(Emergency
3B. Engine
3D. Coolant
items)
oil temperature
tank oil level
temperature
4A. Coolant
level
4B. Battery
charge
4C. Hydraulic
6. Turn signal
lock
pilot lamp
7. Head lamp (High beam)

8. Speedometer
9. Service
meter
10. Service
meter
11. Warning
3E. Air pressure

(Warning
steering
5C. Parking
5F. Differential
warning
oil pressure
3C. Hydraulic
monitor
5E. Accumulator
level
3A. Differential
Caution
235COO2032
5D. Float
tank oil level

oil level
2C. Coolant
4.
5F
5A. Preheater
temperature
Check (Check before
Caution
5E
5. Pilot indicator
Gauge
2B. Engine
3.
5D
indicator
lamp
items)
tank oil temperature
10-147
0
SYSTEM (EVMS)
3E 30 3C 38
3A
4A
2A
48
9
IO
4c
5B
1.
2.
3.
4.
Gauge
IA. Coolant temperature
IB. Fuel level
Check (Check before starting items)
2A. Hydraulic tank oil level
2B. Engine oil level
2C. Coolant level
Caution (Emergency warning items)
3A. Differential oil temperature
3B. Engine oil pressure
3C. Hydraulic tank oil level
3D. Coolant temperature
3E. Air pressure
Caution (Warning items)
4A. Coolant level
4B. Battery charge
4C. Hydraulic tank oil temperature
10-148
0
5. Pilot indicator
5A. Preheater monitor
5B. Emergency steering
5C. Parking
5D. Float
5E. Accumulator
5F. Differential lock
6. Turn signal pilot lamp
7. Head lamp (High beam)
8. Speedometer
9. Service meter indicator
10. Service meter
11. Warning lamp
INDICATION
ON MONITOR
SYSTEM (EVMS)
PANEL
Serial No.: 11001 - 12000

Cate-
Symbol
Indication
Indication
item
Description
range
gory
Hydraulic
Engine
tank oil level
oil level
Below
low mark
level
Below
low mark
Coolant
level
Below
low mark
charge
When charging
defective
Displays when starting switch is turned

to ON with engine stopped.
- Display goes out when normal
+ Display flashes when abnormal
is
Hydraulic tank oil

temperature
At specified temperature or above
Differential
temperature
At specified temperature or above
Engine
Coolant
oil
Displays when engine is running

. Display goes out when normal
. Display flashes when abnormal
lamps flash at same time
oil level
Below
low mark
temperature
Above
105C
Air pressure
Below specified
pressure
Speedometer
0-
High beam
When
100 km/h
Displays when engine is running

. Display flashes when abnormel;
buzzer and lamp actuated
Digital
display
operated
Displays when starting switch
Lights up when operated
Turn signals
Service
meter
Service
meter
(right,
and
Below specified
pressure
oil pressure
Hydraulic
low mark
Coolant
Battery
--0
4D
Below
left)
indicator
When
is turned
ON;
operated
0 - 99999/h
displayed
Actuated
Advances
When
Flashes when
operated
when engine oil pressure is normal

1 for every hour of operation
service
meter
is operating
10-149
0
STRUCTURE
Category
AND
Symbol
FUNCTION
ELECTRONIC
Indication
item
PREHEAT
Emergency
steering
Indication
temperature
MONITORING
SYSTEM
preheating

lights up during preheating
When
operated
Lights up when
operated
;reen
IEVMS)
Description
range
When
Red
Coolant
VEHICLE
emergency
is turned
steering
115OC
102.3-C
97OC
90C One lamp lights up to indicate
is
level
80C
White
67C
FULL
Fuel level
All lamps
Red
EMPTY
L
10-150
0
light up below
indicated
level
ON;
STRUCTURE
Serial
Category
AND
FUNCTION
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
(EVMS)
No.: 12001 and up
Indication
Symbol
Hydraulic
Engine
al
tank
item
Indication
oil level
Below
oil level
low
Below
low
range
Description
mark
Displays when starting
switch is turned
to ON with engine stopped.
Display flashes when abnormal
mark
Coolant
level
Below
low mark
1 Coolant
level
Below
low
s0c000!8
e,.,,
Battery
SAP00522
mark
When charging
defective
charge
is
Hydraulic
tank
temperature
Differential
temperature
Engine
@I~
Coolant
and
At specified
temperature
or above
oil
A specified
temperature
or above
oil
Below specified
pressure
oil pressure
Hydraulic
Displays when engine is running.

Display goes out when normal
Display flashes when abnormal
lamps flash at same time.
oil level
temperature
Below
low
mark
Above
105C
Displays when engine is running.

. Display flashes when abnormal;
buzzer and lamp actuated.
SDP00957
Below specified
pressure
Air pressure
0 - 100 km/h
---
High
When
beam
Digital
display
operated
Lights up when operated.
Turn
signals
(right,
left)
When
is turned
ON;
operated
lDGOOOl4
Service
meter
Service
meter
0 - 99999/h
displayed
Actuated when engine oil pressure is normal

Advances
1 for every hour of operation
When
Flashes
SKD00631
indicator
operated
when
service
meter
is operating
0
SKD00632
10-151
0
STRUCTURE
Category
AND
Symbol
FUNCTION
Indication
ELECTRONIC
item
Indication
VEHICLE
MONITORING
range
SYSTEM
(EVMS)
Description
PREHEAT
When
preheating

lights up during preheating.
Emergency steering
When
operated
Lights up when
operated
Red
El
emergency
is turned
steering
is
115c
lOZf3'C
al
97-c
Coolant temperature
Green
90"c
One lamp lights
up to indicate
level
80"c
SDP00957
White
67C
SWG00461
FULL
;reer
Fuel level
All lamps
SAD00712
led
EMPTY
SWG00462
10-152
0
light
up below
indicated
level
ON;
STRUCTURE
TRANSMISSION
AND
TRANSMISSION
FUNCTION
CONTROL
CONTROLLER
1.
2.
cN3
CN4
CNl
Display window
Connector
cN6
cN2
2
Outline
The transmission controller controls the system,
and has a built-in computer. When the operator
operates the shift lever, this is transmitted
to
the controller, and the controller observes the
condition of the machine and shifts to the specified speed range. In this way, it is possible to
prevent excessive load on the transmission
and
engine caused by any failure or mistaken operation by the operator.
Protective functions of transmission
1) Observing disconriections or short circuits
It judges if there is any abnormality
in the
transmission
switch signals and uses a double system to prevent damage to the transmission clutches.
If there is any abnormality,
it carries out control to prevent the clutch for that speed range
from being meshed.
10-154
0
SYSTEM
SWCOO388
2)
3)
Prevention
of overrun of engine or transmission
When the transmission
is shifted down, it
judges if there is overrun of the engine or
transmission,
and does not shift down until
the travel speed will not cause any overrun.
If the machine is accelerated with the clutch
still partially engaged (acceleration
caused
by the weight of the machine when traveling
down hill), it shifts up at above the travel
speed that is dangerous for the speed range
for the lever position.
Observing excessive inching load
It calculates the temperature
of the clutch
and plate from the length of time that the
clutch is partially engaged,
and warns of
overheating
of the clutch.
STRUCTURE
AND
FUNCTION
Shift lever position
TRANSMISSION
and transmission
controller
Parking
lamp
Parking
brake
Backup
buzzer
Starting
motor
Differential
SYSTEM
output
Controller
F
CONTROL
output
(0: output)
/ 4 / L / H j ST 1 FB 1 DF 1 PB 1 PL 1
lock solenoid
Transmission
H clutch
solenoid
Transmission
L clutch
solenoid
Transmission
4 clutch
solenoid
Transmission
3 clutch
solenoid
Transmission
2 clutch
solenoid
Transmission
1 clutch
solenoid
Transmission
R clutch
solenoid
Transmission
F clutch
solenoid
10-155
0
SENSORS
SENSORS
Display (use) category
Q Q
Q Q
Q
Q Q
Q
Q
Q
Q Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
10-156
(6)
Type of sensor
Sensor method
When normal
When abnormal
Coolant level (Sub-tank)
Contact
ON (Close)
OFF (OPEN)
Coolant level (Radiator upper tank) (if equipped)
Contact
OFF (OPEN)
ON (Close)
Engine oil pressure
Contact
OFF (OPEN)
ON (Close)
Engine water temperature
Resistance
Hydraulic oil temperature
Resistance
Final drive oil temperature
Resistance
Transmission oil temperature
Resistance
Speedometer
Pulse
Engine speed
Pulse
Resistance
Air pressure
Contact
ON (Close)
OFF (OPEN)
Engine oil level
Contact
ON (Close)
OFF (OPEN)
Hydraulic oil level
Contact
ON (Close)
OFF (OPEN)
Fuel level
Resistance
Shift potentiometer
Resistance
Inching potentiometer
Resistance
Air pressure (for air pressure gauge)
023502
Transmission controller
Gauge
Caution 2
Caution 1
Check before starting
Machine monitor
SENSORS
COOLANT LEVEL SENSOR
1.
2.
3.
4.
Sub-tank
Float
Sensor
Connector
023502
Function
The coolant level sensor is
installed to the radiator
sub-tank. If the coolant
goes below the specified
level, the float goes down
and the switch is turned
OFF. The warning lamp
then flashes.
COOLANT LEVEL SENSOR (IF EQUIPPED)
1.
2.
3.
4.
5.
Float
Sensor
Tube
Wire
Connector
Function
The coolant level sensor is installed to the radiator upper-tank. If the coolant goes below the
specified level, the float goes down and the
switch is turned OFF. The warning lamp then
flashes.
10-156-1
(6)
STRUCTURE
ENGINE
AND
OIL PRESSURE
SENSORS
FUNCTION
SWITCH
6
1.
2.
3.
4.
5.
6.
Plug
Contact ring
Contact
Diaphragm
Spring
Terminal
Function
.
The engine oil pressure switch is installed to
the engine cylinder
block. It uses a diaphragm to detect the oil pressure, and when
it goes below the specified
pressure, the
switch is turned ON. The engine oil pressure
indicator lamp lights up to warn of the abnormality.
ENGINE WATER TEMPERATURE

SENSOR
TRANSMISSION
OIL TEMPERATURE
SENSOR
FINAL DRIVE OIL TEMPERATURE
SENSOR
HYDRAULIC OIL TEMPERATURE
SENSOR
1
@&-
1.
2.
3.
Connector
Plug
Thermistor
@%!I
Composition
of circuit
SBPO0379
Function
.
The engine water temperature
sensor is installed
to the right side of the engine.
Thermistor
(3) detects the temperature
and
sends a signal to the monitor panel. The
monitor panel displays the water temperature according to that signal. If the temperature goes above the specified temperature,
the warning
lamp flashes and the alarm
buzzer sounds to warn of the abnormality.
.
The hydraulic oil temperature
sensor is installed to the hydraulic tank and the final
drive oil temperature
sensor is installed to
the final drive case. They send a signal to

the monitor panel. If the temperature
goes
above the specified temperature,
the warning lamp flashes
and the alarm
buzzer
sounds to warn of the abnormality.
The transmission
oil temperature
sensor is
installed to the transmission
oil piping and
sends a signal to the transmission
controller. If the temperature
goes above the specified temperature,
the warning lamp flashes
and the alarm buzzer sounds to warn of the
abnormality.
STRUCTURE
AND
FUNCTION
SENSORS
SPEEDOMETER
SENSOR
ENGINE SPEED SENSOR
c1
20 a
I
ii
._.
0
b
1.
2.
3.
4.
5.
Magnet
Terminal
Case
Boot
Connector
AIR PRESSURE
1.
2.
lo-158
0
--?
5
F9
0.85fG
0.85fG
1
2
c
Structure
of circuit
SEW00289
Function
.
The speedometer
sensor is installed
to the
transmission
output gear. A pulse voltage
is
generated
by the rotation
of the gear teeth,
and the signal is sent to the machine
monitor to display the travel speed.
.
The engine speed sensor is installed
to the
ring gear portion
of the flywheel
housing.
A pulse voltage
is generated
by the rotation
of the gear teeth, and a signal is sent to the
transmission
controller.
SENSOR
Connector
Frame
Function
.
The air pressure sensor is installed to the air
tank. Any change in the air pressure
inside
the air tank is converted
to a change in the
resistance,
and a signal
is sent to the air
pressure gauge to display the air pressure.
STRUCTURE
AND
AIR PRESSURE
FUNCTION
SENSORS
SWITCH
Construction
of
circuit
1.
2.
3.
4.
5.
Plug
Diaphragm
Switch
Wire
Connector
1.
2.
3.
Connector
Bracket
Sensor
Switch
swcoo447
Function
.
The air pressure switch is installed to the air
tank. The diaphragm
detects the air pressure, and when it goes below the specified
pressure, it shuts off the electric current from
the machine monitor. The warning
lamp then
flashes, and the alarm buzzer sounds.
ENGINE
OIL LEVEL SENSOR
4.
Composition
circuit
of
SBPOO376
10-159
0
STRUCTURE
AND
HYDRAULIC
OIL LEVEL SWITCH
SENSORS
FUNCTION
1.
2.
3.
4.
Float
Switch
Plug
Connector
Construction
of
SWG00448
circuit
Function
The hydraulic oil level switch is installed to
the hydraulic tank, and the float moves up
and down according to the oil level. If the oil
goes below the specified level, the switch is
turned OFF, the warning lamp flashes, and
the alarm buzzer sounds.
FUEL LEVEL SENSOR
1.
2.
3.
4.
5.
6.
7.
Structure
of
circuit
A-A
Function
.
The fuel level sensor is installed to the
center of the front face of the fuel tank.
Float (2) moves up and down according
to the fuel level.
As the float moves up and down, arm (3)
actuates a variable
resistance,
and this
sends a signal to the sub monitor to display the fuel level.
10-160
0
SBD02295
Connector
Float
Arm
Body
Spring
Contact
Spacer
STRUCTURE
AND
SENSORS
FUNCTION
SHIFT POTENTIOMETER
INCHING POTENTIOMETER
1.
2.
3.
Construction
of
circuit
Lever
Sensor
Connector
ua
I
//
i,,
SWG00449
Function
.
The shift potentiometer
is installed to the
shift lever, and sends a signal to the transmission controller according to the amount
that the lever is operated. The transmission
controller controls the speed range of the
transmission
according to this signal.
The inching potentiometer
is installed to the
inching linkage at the transmission end, and
sends a signal to the transmission controller
according to the amount that the inching
pedal is depressed. It is used to detect inching overload.
lo-161
0
STRUCTURE
AND
ENGINE
FUNCTION
ENGINE STARTING
STARTING
CIRCUIT
CIRCUIT
Serial No.: 11001 - 11030
Engine
staD
lnator
relay
Monitor
module
@
\
Non-continui
port ion
(hatched
Parking
brake
DO,
End
lamp
_
start Ina
Alternator
motor
Fuse
box
Transmission
control
box
CN-RST
Rotary
switch
Start
motor
ins
relay
SWG00450
10-162
0
STRUCTURE
AND
FUNCTION
ENGINE
STARTING
CIRCUIT
Function
Starting motor terminal E is separated from the
ground only when the shift lever is at the neutral position, the parking switch is ON, and the
starting relay coil is energized. If it is not in this
condition, it is impossible to start the engine.
Operation
1. When the starting switch is turned to the
ON position, electricity flows from battery
+ starting switch terminals
B - BR + engine stop motor relay terminals
1 - 2 +
ground, and the relay coil is energized.
2.
3.
4.
The electric current from the battery flows

from engine stop motor terminals A - B +
relay terminals 5 - 3 + motor, and rotates
the motor.
When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal B, the circuit from terminal A to B opens,
and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the
continuous
portion of terminal
D contacts
terminal B, both poles of the motor are connected to the ground, and the motor stops
rotating.
In this condition, the engine stop motor cable is completely extended, and the fuel injection pump lever is set to the FULL position to place it in the operating condition.
5.
In addition, the current flows from starting

switch terminal BR + battery relay coil -+
ground,
and the battery
relay switch
is
closed.
6.
Furthermore,
if the shift lever is at the neutral position, electric current flows from the
battery relay + fuse + starting motor relay
(CN RST) terminals
1 - 2 + rotary switch
terminals
2 - 11 + ground, and the relay
coil is energized.
7.
If the parking brake switch is turned to the

relay + fuse + parking switch terminals 1 2 + starting motor relay (CN RST) terminals
1 - 2 + ground, and the relay coil is energized.
8.
In this condition,
if the starting switch is
turned to the START position, electric current flows from starting switch terminals B C + starting motor terminal S + terminal E
+ starting motor relay (CN RST) terminals 5
- 3 + starting motor relay (CN RST) terminals 3 - 5 + ground.
9.
A circuit is formed from the battery + battery relay + starting motor terminal B, so
the engine starts.
If the shift lever is not at the N position,
electricity is not supplied to terminal
1
of the starting motor relay (CN RST).
Terminals
3 and 5 of the relay remain
open, so the circuit in Item 6 is not
formed, and the engine does not start.
In addition, if the parking switch is not
ON, electricity is not supplied to terminal 1 of the starting motor relay (CN
RPST). Terminals
3 and 5 of the relay
remain open, so the circuit in Item 7 is
not formed,
and the engine does not
start.
10-163
0
STRUCTURE
Serial
AND
FUNCTION
No.: 11031 - 12012,
ENGINE
STARTING
CIRCUIT
12016 - 12018
Engine
stop
motor
relay
Monitor
II
module
CN-25
I I
CN-PL
Parkine
brake
End
IamP
Service
meter
StartIn
Alternator
motor
Fuse
box
Transmission
control
box
Rotary
switch
Startin
motor
rel
Parklna
brake
rel
SWG0045
lo-164
0
STRUCTURE
AND
FUNCTION
ENGINE
STARTING
CIRCUIT
Function
ground only when the shift lever is at the parking position and the starting relay coil is energized. If it is not at the parking position, it is
impossible to start the engine.
Operation
--f starting switch terminals
B - BR + engine stop motor relay terminals
1 - 2 -+
2.

the motor.
3.
continuous
portion of terminal
D contacts
rotating.
4.
In this condition, the engine stop motor cable is completely

extended, and the fuel injection pump lever is set to the FULL position to place it in the operating condition.
5.

switch terminal
BR -+ battery relay coil +
ground,
and the battery
relay switch is
closed.
6.
Furthermore,
ing position,
battery relay
terminals 1 11 + ground,
7.
In this condition,
turned to the START position, electric current flows from starting switch terminals B C -+ starting motor terminal S + terminal E
-+ starting motor relay terminals
3 - 5 +
ground.
8.
A circuit is formed from the battery + battery relay + starting motor terminal B, so
the engine starts.
.
if the shift lever is at the parkelectric current flows from the

+ fuse -+ starting motor relay
2 + rotary switch terminals 1 and the relay coil is energized.
If the shift lever is not at the parking

position, electricity is not supplied to terminal 1 of the starting motor relay. Terminals 3 and 5 of the relay remain open,
so the circuit in Item 6 is not formed,
and the engine does not start.
lo-165
0
ENGINE STARTING CIRCUIT
023502
Serial No.: 12099 12502
10-166-1
(6)
023502
10-166-2
(6)
STRUCTURE
AND
FUNCTION
ENGINE
STARTING
CIRCUIT
Function
ground only when the transmission
controller
recognizes the parking command and the starting relay coil is energized. If the shift lever is not
at the parking position, it is impossible to start
the engine.
Operation
+ starting switch terminals
B - BR -+ engine stop motor relay terminals
1 - 2 -+
2.

the motor.
3.
continuous
portion of terminal
D contacts
rotating.
4.
In this condition, the engine stop motor cable is completely extended, and the fuel injection pump lever is set to the FULL position to place it in the operating condition.
5.

switch terminal BR -+ battery relay coil +
ground,
and the battery
relay switch is
closed.
6.
Furthermore,
if the shift lever is at the parking position, electric current flows from the
transmission controller + starting motor reJay terminals 1 - 2 -+ ground, and the relay
coil is energized.
7.
In this condition,
turned to the START position, electric current flows from starting switch terminals B C + starting motor terminal S + terminal E
+ starting motor relay terminals
3 - 5 +
ground.
8.
A circuit is formed from the battery -+ battery relay + starting motor terminal B, so
the engine starts.
If the shift lever is not at the P position,

electricity is not supplied to terminal
1
of the starting motor relay. Terminals 3
and 5 of the relay remain open, so the
circuit in Item 7 is not formed, and the
engine does not start.
lo-167
0
STRUCTURE
AND
FUNCTION
ENGINE STOPPING
ENGINE
STOPPING
CIRCUIT
CIRCUIT
Serial No.: 11001 - 11030

CN-53
CN-15
Engine
stop
motor
relay
Monitor
module
I/I/
Parking
brake
(hatched
portion)
lamp
Service
meter
CN-SH
StartIne
Alternator
motor
c
t
______.._.__
~__._
-.-..-.-
-----Transmission
control
box
-~~
_.__.__ ~_
CN-RST
Rotary
switch
Start
motor
ine
relay
SWG00453
lo-168
0
STRUCTURE
AND
ENGINE
FUNCTION
Serial No.: 11031 - 12012,
STOPPING
CIRCUIT
12016 - 12018
CN-53
CN-15
Engine
stop
motor
relay
Monitor
module
CN-25
II
ir
Engine
stop
motor
Non-continuity
port ion
(hatched
portion)
End
Parking
brake
IamP
Startin
snitch
Service
meter
Transmission
control
box
Rotary
switch
Start
motor
Parking
brake
ino
relay
relay
SWG00454
1O-l 69
0
ENGINE STOPPING CIRCUIT
023502
Serial No.: 12099 12502
10-171
(6)
023502
10-172
(6)
023502
10-173
(6)
20
TESTING
AND ADJUSTING
...............
...............
Standard
..............
Tool list for testing and adjusting
.........
Testing and adjusting valve clearance
pressure ..............
compression
Measuring
.....
Testing and adjusting fuel injection timing
pressure
..................
blow-by
Measuring
engine oil pressure .................
Measuring
exhaust gas color ..................
Measuring
...........
exhaust gas temperature
Measuring
pressure
(boost
Inching
belt tension
20-16
20-17
20-18
20-19
stop
20-20
..................
control
accelerator
20-22
20-23
....................
locking
differential
20-21
.......
force
and operating
transmission
HYDROSHIFT
20-15
..............................
pedal travel
Checking
20-I 2
20-14
.............
the engine
for adjusting
motor cable
Adjusting
20-I 1
) ..........................
and adjusting
Procedure
20- 8
20-10
air pressure
intake
Measuring
20- 4
table for chassis
value
Testing
20- 3
value table for engine
Standard
device
20-24
...............................
oil pressure
20-25
Steering
..............................
..........................
Checking tire runout
Checking air pressure of tire ...................
Checking toe-in ...............................
of articulate center pins ............
Installation
system
Checking
Checking
parking
Checking
work
Checking
work
Charging
Adjusting
Bleeding
Adjusting
Adjusting
.................
............
20-30
20-30
oil temperature
equipment
20-31
........................
pressure
equipment
........................
hydraulic
......................
with gas ..........
blade accumulator
.....................
blade lift speed
pump
.............
air from hydraulic
slip load of circle rotation clutch .....
hydraulic
Measuring
force
and operating
work
20-29
20-29
.......................
control lever
equipment
hydraulic
Adjusting
20-28
brake
Checking
hydraulic
20-26
20-27
of brake disc ...................
wear
travel
20-26
pressure
drift
module
speedometer
machine
monitor
TROUBLESHOOTING
20-32
20-33
20-34
20-35
20-36
of
..........................
.
20-31
30-38
.
_. 20-39
20-l
A
A
When
carrying
out
testing
pins, block the wheels,

When
carrying
thorized
When
spurt
out
person
checking
out
and
and
adjusting,
and apply
or troubleshooting,
the parking
operations
with
two
stop
the
machine
on level
ground,
fit safety
brake.
or more
workers,
always
use signals,
and
do not allow
any
unau-
near the machine.

the
may
water
level,
cause
burns,
if the
radiator
so always
cap
wait
is removed
for
the
when
engine
the
to cool
engine
down
is hot,
before
boiling
checking
water
the
will
water
level.
A
A
A
Be extremely
careful
not to touch
Be extremely
careful
not to get caught
When
removing
release
the
the
internal
any hot parts.

in the fan or any other
plugs
or caps
from
pressure
first.
Fit the
places
under
measuring
rotating
hydraulic
tools
parts.
pressure,
securely
before
water
pressure,
carrying
out
or air pressure,
any
testing,
adjust-
ing, or troubleshooting.
*
When
using the standard
be careful
1.
The standard
standards
mating
2.
values
for new
wear
during
the results
of various
for judgement
in testing,
in the standard
and machines
operation
standard
or as target
values
tests and standard
with the repair
Do not use this standard
20-2
table
adjusting,
or troubleshooting,
it is necessary
to
points.
for the new machines
judgement
together
values
machines
The failure
erence
3.
of the following
values
shipped
values
from
when
in the standard
values
and operation
values
carrying
value
for machines
history
table as a standard
table
the factory.
should
given
as reference
from
be used as values
the
for esti-
out repairs.
table
are values
shipped
of the machine
for judging
are values
They
claims.
from
using
estimated
the factory.
when judging
values
based
Use these values
failures.
on
for ref-
TESTING
AND ADJUSTING
STANDARD
STANDARD
VALUE
TABLE FOR ENGINE
VALUE TABLE FOR ENGINE
Serial No.: 11001 - 12000
Engine
Classifi
cation
Item
Unit
Condition
S6D140-1
Standard
value
Permissible
High idling speed
rpm
2,350 + 50
Low idling speed
rpm
665 + 15
value
2,350 + 50
Engine
Quick acceleration
(Low idling + High idling)
Bosch scale
Max.
5.0
7.0
At high idling
Bosch scale
Max.
1.5
2.5
Intake pressure
(Boost pressure)
See Measuring
intake air
pressure (boost pressure)
kPa ImmHgl
Exhaust
See Measuring
gas temperature
Exhaust
gas color
temperature
exhaust
Max. 54 (405)
Max.
400
43 13201
600
Valve clearance
(When engine is hot
or cold)
Intake valve
mm
0.43
Exhaust
mm
0.80
Compression
pressure
(SAE30 oil)
Oil temperature:
VlPa {kg/cm?
Max. 3.1 I321
2.2 (22)
(rpm)
(160 - 200)
(160 - 200)
:Pa {mmH,OI
Max. 0.98 11001
1.96 {200}
At high idling
WPa {kg/cm2)
0.3 - 0.5 13.0 - 5.01
0.2 (2.01
At low idling
WPa {kg/cm2)
Min. 0.1 il.01
0.07 IO.71
80 - 110
120
(Engine
Blow-by pressure
(SAE30 oil)
valve
40 - 60C
speed)
(Water temperature
operating range)
inside
At rated output
(Water temperature
operating range)
Oil pressure
(SAEBO pil)
All speed
Oil temperature
Fuel injection
timing
Fan belt tension
inside
(Oil in oil pan)
Before top dead center

(B.T.D.C.)
Deflects when pushed with

a force of 58.8 N 16 kg}
values given in the TESTING

AND ADJUSTING
DATA
are NOT for adjustment
of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
The
20-3
0
STANDARD VALUE TABLE FOR ENGINE
TESTING AND ADJUSTING
Serial No.: 12001 and
UD
S6D140E-2
Engine
Classification
Condition
Unit
ga,
High idling speed
mm
2,350 f 50
tm
Low idling speed
mm
650 +;
PC
Item
Standard
value
Engine
Exhaust
Iermissible
value
2,350 + 50
-
Quick acceleration
(Low idling + High idling)
Bosch scale
Max.
4.0
6.0
At high idling
Bosch scale
Max.
1.0
2.0
gas color
Intake pressure
(Boost pressure)
See Measuring
pressure (boost
intake air
pressure)
Exhaust
See Measuring
gas temperature
exhaust
temperature
Min. 78.7 1590)
66.7 1500)
Max. 700
700
kPa {mmHg)
Valve clearance
(When engine is hot
or cold)
Intake valve
mm
0.43
Exhaust
mm
0.80
Compression
pressure
(SAE30 oil)
Oil temperature:
MPa {kg/cm?
Max. 3.8 139)
2.7 f27)
(rpm)
(160 - 200)
(160 - 200)
(Engine
valve
40 - 60C
speed)
8
z
zz
Blow-by pressure
(SAEBO oil)
(Water temperature
operating range)
inside
tPa ImmH,O)
Max.
0.98 UOO)
1.96 1200)
At rated output
(Water temperature inside

operating range)
Oil pressure
(SAE30 oil)
Alternator
tension
MPa (kg/cm?
0.3 - 0.5 (3.0 - 5.0)
0.2 (2.0)
At high idling
MPa Ikg/cm*)
3.25 - 0.44 (2.5 - 4.5)t
0.18 (1.8)
timing
(SAE IOW)
At low idling
(SAE 30)
MPa Ikg/crr+)
0.12 (1.2)
0.07 (0.7)
At low idling
(SAE IOW)
MPa {kg/cm?
0.10 (1.0)
0.07 (0.7)
All speed
Oil temperature
Fuel injection
At high idling (SAE 30)
(Oil in oil pan)
Before top dead center

(B.T.D.C.)
degree
belt
Fan belt tension
80-
110
16 + 0.5
13Deflects when pushed with

a force of 58.8 N 16 kg)
120
16 + 0.5
16
mm
17 - 19
The values given in the TESTING AND ADJUSTING

DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
20-3-l
TESTING
STANDARD
ADJUSTING,
AND ADJUSTING
VALUE TABLE FOR TESTING AND

FAILURE JUDGMENT
OF CHASSIS
STANDARD VALUE TABLE FOR TESTING AND ADJUSTING,

FAILURE JUDGMENT OF CHASSIS
Compo
nent
Accelerator
pedal
. Engine stopped
. Up-down movement at joint
between pedal and pin
. Stroke from center of knob
Fuel control
lever
mmI
160 + 10
160 f 20
Height H from floor to center

of pedal mounting bolt
mmL
TOGO0001
Operating
. Engine stopped
. Max. value to just before end of travel
effort
. Up-down
Travel
Operating
movement
of pedal
. Engine stopped
. Max. value to just before end of travel
effort
. Engine stopped
. Travel at tip of lever for each
speed range
Travel
. Engine at full throttle

. Lock brake
. Set transmission at highest speed
Slippage of
transmission
range, then release inching pedal

and measure time until engine stalls
Main oil
pressure
Lubrication
. Engine
127.5 5 19.6
{I3 rt 2)
60 f 5
mm
Play of steering
wheel
20-4
0
Max. 65
&I
13.0
29.4 +f 0.51
4.9
mm
27f
set
13.0
29.4 *f 0.5)
4.9
10
27+
Max. 3.0
12
Max. 3.0
at full throttle
40 - 60C
. Oil temperature:
oil
I
Oil pressure
127.5 f 49.0
{13 + 51
. Engine at full throttle

. Transmission: Neutral
. Differential: Locked
. l$a14$$e
oil temperature:
. Raise front tires 50 - 100 mm

from ground
. Turn steering wheel and
measure distance to point
where wheels start to turn to side
I
2.5
MPa
g/cm)
mm
1.1 f 0.1
{II f I}
$01
25-45
+0.5
I25 +;
Max.45
TESTING
)Compc
nent
STANDARD
ADJUSTING,
AND ADJUSTING
Measurement
Item
conditions
Unit

FAILURE JUDGMENT
OF CHASSIS
Standard
value
for new machine
Service
limit
value
. Raise front tires 50 - 100 mm

from ground, check point where
steering wheel starts to turn,
then turn steering wheel fully and
measure distance to point where
steering wheel stops turning
Check distance to both IefI and right
Turning
angle
(lock-to-lock)
Operating
effort
steering wheel
Runout
. Serial No.12001 and up
Max.
Max. 59
{Max. 61
Max.
Front tire
MPa
Rear tire {kg/cm21
0.24
12.451
0.24
i2.451
0.25
12.61
0.25
12.61
-----I
. Flat, paved
Toe-in
Leaning
road surface
I I
angle
Priority flow
divider relief valve
Engine
deg
. Engine
at low
fully
idling
313.8 k 19.6
{32 * 21
I
I
19.5 rt 1.5
17.2 + 1.0
U75 f 101
Max. 490
{Max. 501
locked
Stopping
distance
. Stopping distance when brakes are
Parking brake holding

performance
. Tire slip limit when
applied at travel speed of 32 km/h

(SAE J 1473)
brake
parking
is locked
. Engine
Air pressure
19.5 + 1.5
17.2 k 0.5
1175 + 51
at full throttle
. Measure at center of pedal

. Measure when wheels are
Operating effort of
brake pedal
2
I=
mm
Front tire
MPa
. 18.00-25-12PR
. Serial N0.11001 - 12000 Rear tire {kg/cm3
Camber
5.7 f 1.0 turns
Max. 49
{Max. 5)
. Put a dial gauge in contact with

side wall of both front and rear
tires and measure runout
of tires
Tire inflation
pressure
5.7 + 0.5 turns
. Engine at low idling

. When traveling in Fl
of
. 23.5-25-12PR
$
I] g
SE
Z
ot
$
deg
MPa
(kg/cm21
at full throttle
Max. 16
(SAE J1473)
Min.
20
0.41 - 0.93
I4.2 - 9.51
Max. 22.8
(SAE J 1473)
Min.
15
Max. 0.36
{Min. 3.7)
Leaning
N H
N H
Left
Right
30 + 5
30 f
Articulating
N H
N H
Left
Right
35 + 5
35 + 10.0
Blade lift
(left, right)
N ti
N H
RAISE
LOWER
30 + 5
30 f 10.0
N tf
N tf
Left
Right
30 + 5
30 * 10.0
Left
Right
30 f 5
30 + 10.0
Blade
side shift
. Engine:
Stopped
. . Measure
Drawbar
shift
side
at
tip of lever
10.0
mm
N tf
N ti
Circle
rotation
N ++ Left
N tf Right
30 * 5
30 + 10.0
Power
tilt
N ti Tilt forward
N H Tilt back
35 f 5
35 f
N t;, RAISE
N tj LOWER
35 f 5
35 * 10.0
Ripper
10.0
20-5
0
STANDARD VALUE TABLE FOR TESTING AND

ADJUSTING, FAILURE JUDGMENT OF CHASSIS
Compc
nent
Item
Measurement
Leaning
Articulating
Blade lift
(left, right)
Blade side shift
. Engine:
Stopped
. Max. value
to end of
travel
Standard
value
LJnit for
new machine
conditions
I
I
N t)
N t)
Left
Right
N tf
Left
Right
N tj
N t)
RAISE
LOWER
N tf
N H
Left
Right
N tf
N tf
Left
Right
limit value
19.6 - 34.3
{2 - 3.5)
Max. 39.2
{Max. 4.0)
14.7 - 29.4
{I .5 - 3.0)
{Max.
Max. 39.2
4.0)
19.6 - 34.3
{2 - 3.5)
Max. 39.2
{Max. 4.0)
Right
19.6 - 34.3
I2 - 3.51
Max. 39.2
{Max. 4.0)
Power tilt
N ++ Tilt forward
N tf Tilt back
14.7 - 29.4
{I .5 - 3.0)
Max. 39.2
{Max. 4.0)
Ripper
N tf
N tf
14.7 - 29.4
11.5 - 3.0)
Max. 39.2
{Max. 4.0)
130 + 15
130 + 15
Drawbar
shift
side
N tj Left
Circle rotation
Blade lifting
speed
Blade side shift

speed with
movement
of
circle
N t)
RAISE
LOWER
. Enaine: Rated soeed

. Hydraulic oil
temoerature:
40 & 5C
. Time taken to move
bottom
edge of blade
between 50 and 100
mm from ground
RAISE
LOWEf
. Engine: Rated speed

. Hydraulic oil
temperature:
40 & 5C
Left
. Set height of bottom
edge of blade to 100
mm with blade at center
as standard condition
. Side shift speed to left and Right
right when shifting 200 mm
horizontally with circle

. Hydraulic oil
temperature:
Blade side shift
40 + 5C
Left
. Set height of bottom
speed
compared
to circle
Ripper lifting
speed
Blade rotation
speed
130 * 15
130 + 15
edge of blade to 100

mm with blade at center
as standard condition
Side shift speed to left and Right
right when shifting 200 mm
horizontally with circle

. Hydraulic oil
20-6
0
Service
RAISE
temperature:
40 f 5C
Speed to raise tip of
center ripper shank
LOWEf
between 50 and 150 mm
. Blade angle speed

with engine at
full throttle
. Hydraulic oil
temperature:
40 f 5C
Serial
No.
11001 - 1205C
Serial No.
12051 and up
:::::
100 * 15
100 * 15
TESTING
Compc
nent
STANDARD
ADJUSTING,
AND ADJUSTING
Measurement
Item
conditions
Unit

FAILURE JUDGMENT
OF CHASSIS
Standard value
for new machine
iervice
limit value
. Hydraulic
Hydraulic
of blade
drift
Hydraulic drift
of chassis when
gc;;d
up with
oil temperature:
40 f 5C
Downward
movement
of
cylinder when blade is
suspended at right angle to
chassis and equally extended
to left and right
Max. 10
Max.
10
Max.
10
Max.
IO
Max.
20
Max. 20
. Engine: .Rated speed

. i$p5uF
011 temperature:
0
. Downward
movement
of
cylinder when blade is lowered I
to ground and used to raise
front wheels from ground
,
. Hydraulic
Hydraulic
of ripper
drift
Hydraulic drift
of chassis when
pushed up with
ripper
Priority valve
pressure
oil temperature:
40 * 5C
Downward
movement
of
cylinder when ripper is
suspended

. Hydraulic oil temperature:
40 I?z5C
. Downward
movement
of
cylinder when ripper is lowerec 1
to ground and used to raise
and rear wheels from ground
Main control valve

relief pressure
Max.
20
24.5 f 1.0
1250 f 10)
24.5 + 1.5
1250 + 15)
Right valve
24.5 f 1.0
{250 + IO}
24.5 f 1.5
(250 I!C151
Left valve
24.5 + 1.0
{250 + 101
24.5 + 1.5
{250 I!I 151
relief
. Engine at full
throttle
. Hydraulic oil
temoerature:
40 F 5C
Max. 20
20-7
0
TESTING
STANDARD
ADJUSTING,
AND ADJUSTING
Item
Measurement
conditions
Unit

FAILURE JUDGMENT
OF CHASSIS
Standard value
for new machine
Service
limit value
1st
4.0 f 5 %
4.0 f 10 %
2nd
5.4 f 5 %
5.4 f 10 %
3rd
8.0 + 5 %
8.0 f 10 %
4th
11.5 f 5 %
11.5 + 10 %
5th
15.8 + 5 %
15.8 + 10 %
6th
21.4 + 5 %
21.4 rt 10 %
31.3 * 5 %
31.3 * 10 %
44.9 * 5 %
44.9 f 10 %
4.3 + 5 %
4.3 f 10 %
2nd
5.8 f 5 %
5.8 f 10 %
3rd
8.5 + 5 %
8.5 f 10 %
4th
12.2 * 5 %
12.2 L!z10 %
5th
16.9 +z 5 %
16.9 f 10 %
6th
22.8 + 5 %
22.8 f 10 %
7th
33.4 XL5 %
33.4 f 10 %
8th
47.9 + 5 %
47.9 f 10 %
Forward
7th
. Flat and dry road surface

. Oil temperature and pressure
in operating range
. Engine at rated speed
. No load
. ~;;irressure
of tire in specified
8th
1st
km/h
Reverse
Engine
water
E
2
cooling
Engine oil
temperature
Transmission
. Oil and water levels are normal

. Air temperature
40C
. Continuous traction IF-21
. On a concrete road surface
. Using thermistor
Performed with thermostat
open
oil
z
z!
Tandem case oil

temperature
20-7-l
0
Max.102
Max.
102
799-205-1100
Tachometer kit
6 99999.9 rpm
2.5, 6, 40, 60 MPa

{
790-261-1204
60 MPa
{600 kg/cm2}
{
(5)
799-201-9001
Bosch index : Level 0 9
799-401-2311
200 kPa {1,500 mmHg}
79A-264-0091
0 490 Nm {0 50 kg}
79A-264-0021
0 294 Nm {0 30 kg}
Tachometer kit
799-205-1100
6 99999.9 rpm
2.5, 6, 40, 60 MPa

{
79A-264-0021
0 294 Nm {0 30 kg}
0 1 MPa {0 10 kg/cm2}
0 1,080 Nm {0 110 kg}
(5)
TESTING
Ir
Adjust
AND
clearance
crosshead
Intake
Remove
2.
Rotate
pulley.
intake
with
3.
head cover
with
When
valve
rotating,
No.
center,
adjust
crankshaft
check
1 cylinder
marked
of
(at 20C)
mm
direction
mark
the
of
to align
crankshaft
movement
in the normal
Set
top dead center.
marked
top
of the
and No. 6 cylinder.
is at compression
the valves
to compression
the valves
TOP
at compression
one turn
cylinder
1.6
of No. 1 cylinder
When
top
and
(1).
in the normal
the
No. 1 cylinder
valve
0.80
the crankshaft
(2)
lever
Exhaust
mm
cylinder
pointer
rocker
CLEARANCE
value.
(at 20C)
0.43
1.
between
to following
valve
VALVE
ADJUSTING
top
. Then
direction,
dead
center,
dead
rotate
Valve
the
set No. 6
and adjust
o.
I
4.
To adjust,
insert
tool
F between
crosshead
(4) and
turn
clearance
is a sliding
fit.
Tighten
locknut
(6) to
rocker
adjustment
hold
adjustment
lever
screw
(3) and
(5)
screw
sition.
w
20-l 0
0
Locknut:
arrangement
58.8 i
5.9 Nm (6.0 + 0.6 kgm)
until
in po-
TDD00714
5.
Then
rotate
one
turn
maining
*
the crankshaft
and
adjust
valves
After
marked
adjusting
top
dead
in the normal
the
valve
center,
1 cylinder
it is also
120
clearance
of each
for
by
the
re-
o.
No.
crankshaft
direction
clearance
each
time
cylinder
at compression
possible
to turn
and adjust
according
the
the valve
to the firing
order.
Firing order:
After
1 -
tightening
5 -
3 -
the locknut,
6 -
check
2 -
the clearance
F621201068
again.
MEASURING
PRESSURE
A
1.
When
measuring
muffler,
or to get caught
valve
2.
Warm
3.
Remove
4.
Install
6.
see
up engine
nozzle holder
tool
in rotation
pressure,
be
manifold
or
parts.
TESTING
AND
ADJUSTING
gauge
Disconnect
connector
INJECTION
nozzle
(2) of
position,
the compression
the
the
holder
mount,
then
con-
in position.
where
60C).
DI.
and measure
Measure
40 -
assembly.
02 to the
tachometer
NO
exhaust
(oil temperature
Set engine
the
the
CLEARANCE.
nect pressure
5.
touch
clearance.
details,
VALVE
%
2
compression
not
For
to
the
careful
Adjust
*
COMPRESSION
stop
motor
(I),
set
then
crank
the
engine
pressure.
compression
pressure
to
pressure
gauge
at the
indicator
point
remains
steady.
*
When
measuring
measure
within
the
engine
the specified
the
compression
speed
to
confirm
pressure,
that
it is
range.
235FO2057
20-l 1
0
FUEL INJECTION

Serial
There
No.:
are
11001
the
- 12000
following
methods
ing the fuel injection
timing
mark
Aligning
pump
match
to the original
Delivery
valve
tion pump
When
using
the
valve
with
method
assembling
without
when
the
delivery
copper
gasket
new
adjust-
the
injection
repair.
assembling
the
injec-
or replaced.
valve
method,
and
parts.
and
pump.
O-ring
Prepare
always
of the
these
re-
delivery
parts
before
the operation.
Set the
center,
For
when
engine
that has been repaired
place
starting
of testing
of the injection
No. 1 cylinder
at the
compression
top
dead
then test and adjust.
details,
see
TESTING
AND
ADJUSTING
VALVE
CLEARANCE.
Testing
1.
Turn the crankshaft
and adjusting
by aligning
match
mark
back 30 to 45 from
No. 1 cylin-
der TOP.
2.
Turn
the
and
align
damper
3.
crankshaft
pointer
engine
oil
(4), then
pump.
t
After
slowly
injection
(1) with
Remove
flange
the
the
hose
level
4.
Check
that
line
the
engine
fit
If the
the
lines
getting
tube
oil
crankshaft
(3) and
the
level
hose
injection
gauge
plug
tube
to prevent
in.
injection
pump
and
line
are aligned.
are not aligned,
coupling
direction,
on
(5) from
a blind
a on the
b on the coupling
*
gauge
guard
flange,
mud or dirt from
normal
line
(2).
remove
removing
and
in the
timing
to align
the
loosen
lines,
nut
then
(6), move
tighten
the
nut.
D
.
Nut:
Testing
fuel
58.8 f 4.9 Nm (6.0 I 0.5 kgm)
injection
timing
by
delivery
valve
method
*
Prepare
O-ring
new
of the
parts
for
delivery
the
copper
gasket
and
valve
before
starting
the
.operation.
1.
Disconnect
fuel
injection
pipe
(7) of the
der.
2.
Remove
20-12
0
delivery
valve
holder
(8).
No.
1 cylin-
TIMING
3.
Remove
spring
delivery
valve
livery
4.
valve
Remove
(9) and
holder
oil
(4), then
pump.
*
After
the
hose
With
No.
6.
Place
the
rotate
tion
valve
7.
In
the
fit
rotate
control
priming
fuel
in FULL
stops
position,
normal
pump,
where
and
out
423F302
slowly
direction
observe
flowing
the
timing
injection
If the
while
the
of the
outflow
stamp
timing
injection
inspection
with
posi-
delivery
timing
stops,
crankshaft
(2).
passed
through
is late.
stamp
shows
fuel
on
pointer
line
timing
The injection
of
line
stamp
The injection
of adjustment,
After
line
timing
did
not
reach
is advanced.
that
the
injection
timing
is
the
fuel
injection
timing
in
adjust
manner.
the
checking
the spring
Always
replace
O-rings
with
1)
lever
in the
(1) to see if it is aligned
semble
in.
piston
injection
the following
getting
plug
tube
position,
position
If the
If the
out
gauge
direction.
the pointer:
level
a blind
hose
injection
at TOP
the pointer:
*
oil
the
30 to 40 in the reverse
the
the
damper
8
z
z
(3) and
holder.
check
*
de-
prevent
the
when
tube
(5) from
engine
crankshaft
operating
the
the
to
fuel
the
gauge
the
1 cylinder
the crankshaft
(10) from
reassemble
guard
flange,
mud or dirt from
5.
valve
and
level
remove
removing
and
(8),
(8).
engine
flange
delivery
holder
Rotate
and
adjusting,
and the delivery
the
delivery
be
sure
to
reas-
valve.
valve
copper
gasket
and
new parts.
the
direction,
crankshaft
starting
30 to
from
40
in the
TOP position
reverse
in No. 1 cy-
linder.
2)
Align
(I)
the
with
shaft
3)
Loosen
side
nut
slot,
little
pump
until
holder.
Tighten
flange
the
line
on damper
rotating
the
crank-
direction.
injection
and
the
rotate
little
by
no
fuel
nut
on the
pump
flange
operating
flows
out
injection
mounting
on the
of
pump
the
priming
the
delivery
pump
mounting
slot.
Recheck
properly
5)
stamp
(11) on the
by
valve
timing
(2) by slowly
in the normal
flange
4)
injection
pointer
If match
the
injection
timing
to
see
if it
is
adjusted.
marks
a and
b are not aligned,
stamp
new one.
20-l 3
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
FUEL INJECTION
TIMING

1.
Testing
1) Procedure for fixing crankshaft in position
i)
Pull out pin (I), and remove nut (2).
ii) Rotate the crankshaft in the normal direction and align pointer (4) with the fuel
injection line on top of damper (3).
*
When doing this, check that line (5)
on the injection pump camshaft is
near the line on the pump case. If it
cannot be seen, rotate the crankshaft
one more turn.
iii) Push in lock pin (7) towards the engine
and rotate the crankshaft to insert pin
(7) into the hole in gear (8).
2) In this position, check the position of line (5)
on the injection pump camshaft and line (6)
on the pump case.
Note: In this condition, do not start the engine
or try to crank it by force.
2.
Adjusting
If the line in Step l-2) is not aligned, adjust as
follows.
I) Loosen coupling bolts (9) and nuts (IO) at
two places.
2) Rotate camshaft (11) to align line (5) on the
camshaft completely with line (6) on the injection pump case.
3) Tighten bolts (9) and nuts (IO).
w
Nut :
61.25 + 2.45 Nm t6.25 f 0.25 kgm}
3.
Procedure for releasing crankshaft

1) Remove lock pin (7) from the hole in gear
(8).
It If pin (7) is stiff, tighten nut (2) before
removing the pin.
*
Pull the pin out completely toward this
side to a position where it does not
move.
2) Tighten nut (2).
w
Nut, bolt :
31.4 +_3.5 Nm 6.2 + 0.36 kgm1
3) Install pin (I).
EEP01138
BEP01139
BEPOll
20-13-l
0
MEASURING
Measure
the
BLOW-BY PRESSURE
blowby
pressure
under
the
following
conditions.
Temperature
of
cooling
water:
Within
operating
range
Temperature
Set tool
Use tool
Run the
blowby
+
E4
of hydraulic
and El to blowby
E3
to connect
engine
varies
engine.
considered
When
A:
if the
check
defective
blowby,
with
Before
measure
the
dirty
taking
to the
condition
blowby
value
for
problems
such
defective
gas
or deteriorated
measurements,
When
setting
position,
color,
oil.
be careful
measurements,
to the following
is
con-
as excessive
exhaust
any hot parts or rotating
starting
and
according
abnormal,
consumption,
equipment
output
Therefore,
to touch
1)
rated
greatly
and prematurely
A
hose (1).
as follows.
Blowby
nected
55C
tool El and Ez.
at the
pressure
of the
oil
oil: 45 -
not
parts.
set
the
work
posture.
the
work
be careful
equipment
not to let the
in
blade
hit the tire.

B:
For the
drawbar
shift,
tion as the standard

c:
D:
take
the
center
posi-
position.
Shift the blade fully to the right.

Rotate
the
circle
to
give
a propulsion
angle
of 50.
E:
Raise
the
blade
fully
on
both
the
left
and
hold
it at
right sides.
2)
Pull right
blade
lift
lever
(1) back,
and
the end of its stroke.

*
Raise the
right
end
of the
blade,
and
relieve
the circuit.
3)
In the
shift
the
condition
lever
same
in
Step
(2) and
circle
time
the
to
2),
operate
left
rotation
front
to
blade
lever
move
the
left
(3) at
work
equipment.
*
Use
the
left
rotation
amount
blade
left
lever
shift
to
lever
set
the
and
oil
the
circle
Front
Opeate at
same time
discharge
to the maximum.
;),8
-4:%/
3
235FO2059
20-14
MEASURING
For tests
tricity
in the
Measure
the
the exhaust
1)
Fit the filter

Insert
the
haust
pipe,
the
paper.
Remove
the
the engine
gas suction
handle
the
paper
to judge
careful
is warm
the
the exhaust
the
exhaust
compare
ex-
566FO6118
and
gas
with
on
the
Gl
the condition.
exhaust
color,
be
careful
pipe.
color
when
the engine
is warm
is 60C).
the
probe
and secure
2) Connect
the
and
into
suddenly,
METER
the exhaust
(oil temperature
port
engine
to catch
filter
measuring
1) Insert
be
in tool GI.
WITH SMOKE
Measure
color,
when
accelerate
operate
not to touch
*
CHECKER
exhaust
color
paper
the filter
When
tests
pipe.
exhaust
scale provided
for
is 60C).
2)
MEASURING
checker;
meter.
SMOKE
the exhaust
(oil temperature
is no air or elec-
smoke
use smoke
measuring
not to touch
there
handy
WITH HANDY
When
3)
where
use
shop,
MEASURING
field
available,
in a repair
EXHAUST GAS COLOR
in
the
outlet
it to the exhaust
the
probe
of
exhaust
pipe with
hose,
pipe
a clip.
accelerator
switch
plug
and air hose to tool Gz.

*
The
pressure
under
3)
of
the
air
supply
should
be
1.5 MPa (15 kg/cm*).
Connect
the
power
cord
to
power
source
socket.
*
Check
that
the
connecting
4)
Loosen
the
cap
insert the filter

*
Fit the
power
switch
is OFF before
the cord.
nut
of
the
suction
pump
and
paper.
filter
paper
securely
so that
the
ex-
haust gas does not leak.

5)
Turn the powr
6)
Accelerate
7)
time,
depress
relief
valve
and
paper.
Lay
the
filter
gas
color
or
on
ON.
engine
the
the filter
sheets
switch
the
suddenly.
accelerator
catch
the
At
pedal,
exhaust
the
same
operate
gas
color
566FO6120
the
on
G2
paper
top
more)
used
to
of
unused
inside
the
and read the indicated
catch
filter
filter
the
exhaust
papers
paper
(IO
holder,
value.
Fl RM02216A-K
20-l 6
EXHAUST GAS
MEASURING
When
removing
Raise
be caretul
the
water
before
Set tool
installing
not to touch
cooling
ting range
1.
or
ment,
temperature
carrying
6 to exhaust
measuring
equip-
any hot parts.

to
the
opera-
out measurements.
temperature
pickup
connector
(1).
A
When
taking
to touch
2.
Run the
measurements,
engine
at rated
haust temperature
1) Before
output
and
measure
measurements,
to the following
careful
not
parts.
the ex-
as follows.
starting
equipment
A:
be
Wh en
setting
position,
set
the
work
posture.
the
work
be careful
equipment
not to let the
in
blade
hit the tire.

B:
For the
drawbar
shift,

C:
D:
take
the
center
posi-
position.

Rotate
the
circle
to
give
a propulsion
angle
of 50.
E:
Raise
the
blade
fully
on
both
the
left
and
hold
it at
right sides.
s
8
2) Pull right
blade
lift lever
(I)
back,
and

*
Raise the
right
end
of the
blade,
and
relieve
the circuit.
3)
In the
shift
the
condition
lever
same
in
Step
(2) and
circle
time
the
to
2),
operate
left
blade
rotation
front
to
shift
lever
lever
left
(3) at
move
the
work
and
the
circle
equipment.
*
Use the
left
amount
4)
In the
blade
rotation
left
lever
to
set
the
oil
discharge
to the maximum.
condition
in Step
3). measure
the
blowby
Front
pressure.
A
The
blade
moves
so be careful
the
diagram,
lever before
A:
AB
and
there
careful
equipment
B:
AB
during
to avoid
e careful
the
measurement,
the contact
stop
Opeate at
shown
operation
of
in
the
OsF{@J
OoooJ
is any contact.
not
to
let
the
work
hit the main frame.

not
to
let
the
blade
hit
235FO2059
the tire.
235FO2060
20-17
MEASURING
When
removing
be careful
1.
or
installing
not to touch
Install
tool
coupler
(1).
INTAKE AIR PRESSURE (BOOST PRESSURE)
When
to
taking
touch
measuring
equipment,
any hot parts.

intake
pressure
measurements,
measurement
be
careful
not
to
parts.
Note:
Run the engine
use the
from
at a mid-range
self-seal
portion
speed
of the
or above,
gauge
then
to remove
oil
inside the hose.

Insert
the
gauge
movement
about
to open
half-way
the
and
self-seal
repeat
the
remove
the
the gauge
will
and
oil.
*
If there
is any
not move,
2.
Run
the
boost
1)
engine
pressure
Before
at
the
rated
starting
output
and
measurements,
to the following
hose,
be sure to remove
the oil.
measure
the
as follows.
equipment
A:
oil inside
so always
When
setting
position,
set
the
work
posture.
the
work
be careful
equipment
not
to let the
in
blade
hit the tire.

B:
For the
drawbar
shift,

c:
D:
take
the
center
posi-
position.

Rotate
the
circle
to
give
a propulsion
angle
of 50.
E:
Raise
the
blade
fully
on
both
the
left
and
hold
it at
right sides.
2)
Pull right
blade
lift
lever
(1) back,
and

*
Raise the
right
end
of the
blade,
and
relieve
the circuit.
3)
In the
shift
the
condition
lever
same
in
Step
(2) and
circle
time
to
the
blade
left
2),
operate
left
rotation
front
to
shift
lever
blade
lever
left
(3) at
move
the
work
and
the
circle
Front
equipment.
*
Use the
left
rotation
amount
lever
to
set
the
oil
discharge
to the maximum.
235FO2059
20-l 8
4)
In the
condition
in Step
3),
measure
the
boost
pressure.
A
The
blade
moves
so be careful
the
to avoid
diagram,
lever before
A:
Be
during
and
there
AB
the
measurement,
contact
stop
shown
operation
of
in
the
is any contact.
careful
not
equipment
B:
the
to
let
the
work
hit the main frame.
e careful
not
to
let the
blade
hit
the tire.
AA
BA
235FO2060

Serial
1.
No.:
11001
BELT TENSION
- 12000
Fan belt
1)
Testing
Check
the
that
tween
fan
pulley
58.8
deflection
range
pulley
(1)
is
pressed
adjust
belt
is within
portion
belt tension
with
If it
the
central
is not
a be-
adjustment
a force
of
within
approx.
the
standard
the
belt
the belt tension.
Standard
of
when
(2) and
N (6 kg).
value,
2)
the
standard
belt tension:
5 -
9 mm
Adjusting
Use
adjustment
bolt
(3) to
adjust
ten-
sion as follows.
2.
If deflection
is too LARGE, TIGHTEN
bolt
If deflection
is too SMALL,
bolt
Alternator
1)
LOOSEN
belt
Testing
Check
that
standard
tween
is
deflection
when
alternator
pressed
it
the
range
with
not
(4) and
a force
within
of the
central
the
belt
is wihin
portion
accessory
of approx.
the
pulley
be-
(5) is
235FO2062
58.8 N (6 kg). If
standard
value,
adjust
the
belt tension.
*
2)
Standard
belt tension:
8 -
12 mm
Adjusting
i)
ii)
Loosen
belt
tension
adjustment
mount
bolt (7) of alternator
Using
a bar,
the
pull
belt tension,
(6) and mount
alternator
then
bolt
(6) and
(4).
tighten
(4) up to adjust
adjustment
bolt
bolt (7).
20-l 9
0

1.
Fan belt
1) Testing
Check that the deflection of the belt is within
the standard range when central portion a
between fan pulley (2) and belt tension adjustment pulley (I) is pressed with a force of
approx. 98 N {IO kg}. If it is not within the
standard value, adjust the belt tension.
*
Standard belt tension: 17 - 19 mm
2) Adjusting
If the deflection
of the belt is too loose,
tighten adjustment
bolt (3); if the tension is
too tight, loosen adjustment
bolt (3).
TEGOOOOZ
2.
Alternator
belt
1) Testing
Check that the deflection of the belt is within
the standard range when central portion a
between alternator pulley (I) and accessory
pulley (2) is pressed with a force of approx.
98N {IO kg}. If it is not within the standard
value, adjust the belt tension.
Ir Standard belt tension: 13 - 16 mm
2) Adjusting
i) Loosen mounting bolt (3) of the alternator assembly and locknut (4) of the belt
tension adjustment
bolt.
ii) Turn adjustment
nut (5) to move the alternator assembly and adjust the tension
of belt (6). After adjusting, tighten locknut
(41, adjustment nut (5), and alternator assembly mounting bolt (3).
iii) After adjusting the belt tension, check
again that deflection
a of the belt is
within the standard value.
TLD00026
20-19-l
0
PROCEDURE FOR ADJUSTING

MOTOR CABLE
1.
Temporarily
jection
2.
Pull
the
to cable
ball joint
(1).
stop
(3)
ENGINE
pump
non-injection)
to the
to the in-
stop motor
(fuel
ball joint
connected
(2) of engine
injection
STOP
the
attach
pump
THE ENGINE STOP
lever
position,
stop
lever,
to
the
temporarily
then
attach
fix the
cable
to
the bracket.
t
t
The
engine
stop
pulled
condition.
When
the
lever
OPERATING
3.
Turn
engine
ated
to
confirm
there
is
stopper
*
that
Be
the
The engine
the engine
stop
stop
lever
ON and
engine
between
is housed
in the
is in the
spring).
switch
especially
clearance
when
the
(built-in
starting
smoothly.
cable
is free,
position
the
times
motor
OFF a few
stop
motor
actu-
to
confirm
that
sure
the
stop
lever
and
is stopped.
motor
has built-in
limit
switches
on both sides of the cable stroke.

*
When
the
in the
into
engine
engine
the
is running,
stop
injection
motor
pump
there
cable.
actuates
is some
A
spring
to
hold
opening position.
.
Engine stop motor stroke:
35 mm
.
Injection pump stop lever stroke:
30 mm
20-20
slack
built
the
23
ADJUSTING
ACCELERATOR
CONTROL
A-A
235FO2064
Procedure
1.
for adiustinq
_
Fix stopper
- accelerator
control
bolt (2) at the standard
height
from
the
6.
After
Standard
height
of stopper
bolt:
spring
56 mm
or
2.
Adjust
so that the installed
length
of cable (6) at the
Depress
pedal
(1) until it contacts
then adjust cable mounting

ators
compartment
the engine
4.
Adjust
end so that throttle
hook plate (IO) so that the engine
If the regulator
vibration,
lever
stops.
lever moves back because
tighten
double
(7) to
angle of
nut (11) further
of the
to in-
power.
oper-
lever (5) at
end is at the end of its stroke.
damper
bolt (9) so that reguSTOP, idling, and full
positions.
Standard
Adjust
set regulator
and adjust the mounting
bolt (2),
B atthe
(8) and stopper
speed
5.
stopper
dimension
lator lever (7) gives the engine

l
the engine,
crease the holding
engine end is dimension

A.
.
Dimension A: 307 mm
3.
starting
the STOP position,
floor.
length
the height
the engine
idling
of damper:
346 mm
of the decelerator
position
pedal so that at
the head of decelerator
pedal (3) is level with the top surface
of the floor mat
(if there is no floor mat, level with the top surface
of
the floor).
20-2 1
INCHING
INCHING
PEDAL TRAVEL AND OPERATING
PEDAL TRAVEL
FORCE
CHECK
Use convex rule 0 to measure the length

movement from up to down from beginning
end of depressing inching pedal (I).
of the
to the
i
235FO2065
INCHING PEDAL OPERATING FORCE CHECK

Use push-pull scale @ to measure the maximum
value in the travel to just before the inching pedal
travel end.
CHECKING
HEIGHT
OF INCHING
PEDAL
Using a steel tape, measure height H of the center

of pedal mounting bolt (I) from the floor.
ADJUSTING
HEIGHT
OF INCHING
PEDAL
Adjust the installed length using rod (3) and

yoke (2) at the pedal end so that installed height
H of the center of pedal mounting bolt (I) from
the floor is 98:: mm. When doing this, remove
pin (5) connecting the yoke and lever (4), then
turn the yoke to adjust the length.
t
Check that portion A of the pedal does not
interfere with the floor.
Depress the pedal to the end of its travel, and
adjust stopper bolt (6) at this position. Then
screw in the stopper bolt a further one turn and
lock it in position.
*
Check that portion B of the pedal does not
interfere with the floor.
After the completion
of adjustment,
start the
engine and run it at full throttle. Depress the
pedal and check that the machine does not move
when the gear shift lever is put into Fl.
Depress the service brake pedal and inching
pedal, and put the gear shift lever into F8. From
this position, release the inching quickly, and
check that the engine stalls within 3 seconds.
(Check with the engine running at full throttle.)
20-22
0
235FO2066
2
TOG00004
CHECKING STEERING WHEEL PLAY

When
dard
the play of the steering

value
or vibrates
wheel
abnormally
is outside
the stan-
or pulls, replace
the
steering valve assembly.
CHECKING STEERING WHEEL OPERATING

Using push-pull
scale 0,
measure
FORCE
the operating
force of
the steering wheel.

*
Measure
operating
force
of the steering
the engine idling and with the wheels
wheel
with
on the ground.
F23B01039
20-25
CHECKING
TIRE RUNOUT
FRONT WHEEL CHECK

1.
2.
Start the engine and raise the front wheels off the
ground, using the blade or scarifier as a jack.
Use dial gauge @ to measure the tire runout while
rotating the tire (I 1 by hand.
REAR WHEEL CHECK

1.
2.
3.
4.
Put jacks under the left and right tandem cases, and
raise the rear wheels off the ground.
Put stand @ under the tandem case.
Start the engine and lower the blade to the ground.
Use dial gauge @ to measure the tire runout while

rotating tire (2) by hand.
Always stop the engine before measuring.
CHECKING
TIRE
AIR PRESSURE
OF
Use tire gauge @ to measure the air pressure of front

and rear wheels.
20-26
023502
20-27
(6)
INSTALLATION OF ARTICULATE CENTER PINS

1. Insert the front frame in the rear frame.
Serial No.: 11001 12502
2. Insert center pins (1) and (2), adjust with bottom

nut (4) so that all clearance A are equal, then
tighten the unit.
a For serial No. 12503 and after, install O-rings (7)
to center pins (1) and (2).
3. Tighten top nut (3).
3 Nut (3)
(1st pass): 255 9.8 Nm {26 1 kgm}
(2nd pass): Loosen temporarily and then
tighten to
215 9.8 Nm {22 1 kgm}.
20-28
(6)
023502
4. Set lock plates (5) to nuts (3) and (4) and secure
them with the bolts.
a For serial No. 12503 and after, install washer
(6) between lock plate (5) and frame.
CHECKING
1.
Remove
WEAR
plug (1) of checking
from direction
2.
Depress
hole.
brake pedal to push piston
Confirm
confirm
be seen through
(2) against
plate
disc 14).
that length A in the diagram
In other words,
DISC
hole and peep through
above the checking
(3) and to compress

3.
OF BRAKE
at right is not 0.
that a portion of the disc can
the checking
hole.
Checking hole
CHECKING
CHECKING
1.
PARKING
PARKING
BRAKE
F23EC030
BRAKE
Place the gear shift lever at the P position.
2.
Check that slack adjuster
3.
Check
that
the
brake chamber
angle
(I) works smoothly.
between
push
and slack adjuster
rod (2) of the
(1) is greater
than
90.
ADJUSTING
1.
Rotate
PARKING
worm
shaft
BRAKE
(3) with
a wrench
to adjust
the
clearance.
2.
When
adjusting,
be careful
to turn exactly
one notch
at a time.
20-29
CHECKING WORK
EQUIPMENT
CONTROL LEVER
TRAVEL AND OPERATING
FORCE
CHECK AND ADJUSTMENT
CONTROL LEVER TRAVEL
Use a convex
rule 0
OF WORK EQUIPMENT
and measure
the operating
length
from the center of the knob of lever (1).

*
Measure
The stroke of work equipment
with engine stopped.

control
lever is deter-
mined by the spool travel of the control valve, but the

neutral position of each lever is adjusted
by each rod.
CHECK AND ADJUSTMENT

OF EACH WORK
EQUIPMENT CONTROL LEVER OPERATING FORCE
Use push-pull
scale @ to measure
maximum
value from
the tip of lever (I) to just before the stroke end.

+
Measure
The
with engine stopped.
operating
force
lever is determined
the control
outside
valve
standard
connecting
of the work
equipment
control
by the spring load of the spool on

side. When
the operating
value,
the movement
check
rod. If it is normal disassemble
valve and check the movement
force
is
of the
the control
of the spool.
CHECKING HYDRAULIC
OIL TEMPERATURE
Special
tool
Part number
A
1.
799-101-I
Remove
502
hydraulic
Part name
I QtY
1Thermistor
oil
tank
cap
I
(1)
and
remove
strainer.
When
removing
slowly
to release
in the hydraulic
2.
Insert
sensor
the remainingoil
pressure
tank.
into filling
perature with thermistor
20-30
cap, loosen the oil filler cap
port
and measure
gauge A.
oil tem-
235FO2075
MEASURING
EXTENTION
HYDRAULIC
DRIFT
OF BLADE CYLINDER
Start engine and after the pressure test, bring hydraulic oil temperature
Raise
the
to the 40
blade
right angles
300
& 5C range.
mm
from
to the machine
the
ground
and equidistant
and at
to right
and left.
Stop the engine and leave for 10 minutes.
Use a convex
rule @
to measure
the amount
the
cylinder piston rod has dropped.
RETRACTION
Start
OF BLADE
engine
after
CYLINDER
the pressure
test,
oil temperature
to the 40 & 5C range.
Lower
until
blade
ground,
its
bottom
push the cylinder
about 300
bring hydraulic
edge
touches
the
and float the front wheels
mm off the ground.
Stop the engine and leave for 10 minutes.

Use a convex
amount
EXTENTION
1:
rule @ to measure
at the cylinder
OF RIPPER CYLINDER
Start the engine and test the pressure,

the hydraulic
oil to 40
(If equipped)
then warm
Raise the ripper about 300
3.
Stop the engine and wait for 10 minutes.

tape
0,
measure
up
5C.
2.
steel
the
of sinkage.
mm from the ground.

the
distance
Then using
the
cylinder
piston rod has moved.
RETRACTION
1.
OF RIPPER CYLINDER
Start the engine and test the pressure,

the hydraulic
oil to 40 f
(If equipped)
then warm
up
5C.
2.
Lower the ripper to the ground, then extend the cylin-
3.
Stop the engine and wait for 10 minutes.
der piston or raise the rear wheels about 300

steel
tape
0,
measure
piston rod has moved.
20-32
the
distance
mm.
Then using
th,e cylinder
CHARGING
Special
BLADE ACCUMULATOR
tool
Part name
Part number
A
792-61 O-l 700
Always
Charging
use nitrogen
lator with
1.
when
Remove
plug
charging
assembly
When
fully
3.
(2) from
installing
the
installing
valve
(4) gradually
gauge
charging
the
the
accumulator,
accumulator:
charging
and open valve
in the
assemblv
accumu-
then
install
A.
After
gas
Qty
gas.
Size of joint for connecting

2.
WITH GAS
valve,
TV8
tighten
valve
(3)
(4) fully.
charging
and
valve
the
accumulator
assembly
charging
will
A,
tighten
pressure
be shown
on
of the
pressure
(4).
Charging
pressure:
2.4 +z. MPa

(24 A kg/cm*)
SI
z
z
If pressure
cm*),
gas
from
reaches
If the
kg/cm*),
valve
gauge
loosen
(5) does
valve
the
(3)
not reach
gradually,
cylinder
until
2.4 MPa (24 kg/

and
pressure
charge
with
gauge
(5)
2.4 MPa (24 kg/cm*).

pressure
remove
(3) to
the atmosphere
gauge
registers
hose
release
gas
and adjust
(6).
from
above
Then
the
2.4
MPa
gradually
(24
,_______j____,
loosen
accumulator
into
\.
to 2.4 MPa (24 kg/cm*).
Ii. Accu;;;;iator
A
234F114E
Accumulator joint
Gasket
\
r-i-
t-7
5/8-18UNi
/
TV8
234F1146
TESTING
AND ADJUSTING
ADJUSTING
SPEED
ADJUSTING
BLADE LIFT SPEED
BLADE LIFT
Serial No.: 11001 - 12022

If there is a difference between the left and right
blade lift speeds, or when reducing the lifting speed
on the left and right, adjust as follows.
1.
Loosen the locknut and adjust with adjustment

bolt (1).
*
If there is a difference between the left and
right balde lift speeds, adjust by loosening
the bolt on the fast side to reduce the speed.
* The adjustment bolt has an adjustment range
of 4.8 turns.
TWG002.49

1.
Loosen locknut (3) of the main control valve.

Adjust with adjustment screw (2).
*
If there is a difference between the left and
right blade speeds, adjust by loosening the
adjustment
bolt on the fast side to make it
slower.
m
Locknut : 88.3 + 9.8 Nm 19 * 1 kgml
20-34
0
TWG00250
BLEEDING AIR FROM HYDRAULIC
Lower
the
work
equipment
completely
to
PUMP
the
ground.
1. Remove
hydraulic
tank side cover.
2. Loosen
air bleed
plug (I) of the front
3. Loosen
air bleed
plug (2) of the rear pump.
4. Disconnect
drain
5. Add hydraylic
*
Add
oil from
oil
until
the front
7. Install
air bleed
drain
elbow.
hose (3).
hydraulic
and rear air bleed

oil:
plugs
oil
(4).
9. Run
low
at
10. Run the
blade
engine
11. Loosen
12. Run the
right
*
blade
air bleed
idling,
raise
2 and
and
lower
3 times.
raise
2 -
and
lower
3 times.
plug (5).
engine
the
tank.
and
lift cylinders
at low
blade lift cylinders

Relieve
idling,
lift cylinders
at high
the left and right
from
(1) and (2).
of the hydraulic
engine
out
4.0 Q
8. Install the side cover

the
comes
ports.
3.5 -
hose (3) to elbow
the left and right

z
R
8
drain
the
Hydraulic
Qz
6. Tighten
hose (3) from
pump.
idling,
and
raise
to the end of their
hydraulic
pressure
and
the
left
and
stroke.
bleed
the
air
completely.
13. Tighten
*
air bleed
Run the
system.
plug (5).
engine
Then
to
check
tank and add hydraulic
circulate
the
the
oil level
oil through
in the
the
hydraulic
oil.
ii
!\
._235CD0204E
20-35
TESTING
ADJUSTING
AND ADJUSTING
ADJUSTING
SLIP LOAD OF CIRCLE ROTATION
CLUTCH
CLUTCH
Serial No.: 11001 - 12050

INSPECTION
1. Remove
2.
plug (I).
Make a mark on holder

from the plug hole.
(2) and
lock plate
(3)
F23501402
3.
Make a mark on cover (4) that is on the same

line as the mark on lock plate (3).
I
Mark
heck mark from

lug hole
F23501401
4.
Push the blade against the ground surface so

that the circle does not rotate, lift the front wheels
off the ground or fix the end of the blade in
position.
Method of raising front wheels off ground
1) Lower the work equipment to the ground,
extend the blade lift cylinder further, and
raise the front wheels off the ground.
2) Apply the parking brake.
Front
wheels
raised
off
around
When raising the front wheels off the

ground, put blocks under the frame at
the center of the front axle to ensure
safety.
TWG00300
Edge
of
blade
held
in Position
TWG00301
20-36
0
TESTING
AND ADJUSTING
ADJUSTING
Operate the circle rotation lever and check if the

clutch slips.
METHOD OF CHECKING FOR SLIPPAGE
1) If it slips, the sound of sliding can be heard,
so return the circle rotation lever to the neutral position to stop the slippage.
2) Check if the slippage occurred because the
mark on the cover and lock plate were out
of alignment.
*
However, if the angle of misalignment
is
within 20, consider that it is not slipping.
ADJUSTING
1. When clutch does not slip.
1) Loosen bolts (I) and add 0.2 mm shim (2).
2) Tighten bolts (1) in the order of tightening.
3) Refer to the procedure for inspection, and
repeat Steps 1) and 2) until there is slippage
to align to the slippage limit point.
2. When clutch slips.
1) Loosen bolts (I) and remove 0.2 mm shim (2).
2) Tighten bolts (I) in the order of tightening.
3) Refer to the procedure for inspection, and
repeat Steps I) and 2) until there is no more
slippage.
When the slippage stops, loosen bolt (I),
add one 0.2 mm shim (21, and align with the
slippage limit.
*
If a shim is added, the pushing force of
the belleville
spring becomes
smaller,
and it is easier for the clutch to slip. If a
shim is removed, the pushing force of
the belleville spring becomes larger, and
it is difficult for the clutch to slip.
BREAKING IN CLUTCH
.
When the clutch disc is replaced with a new
part, break in the clutch as follows.
Adjust in Steps 1 and 2 above to align to the
slippage limit point.
2) Make the clutch slip for 3.5 - 4.0 seconds.
.
Run the engine at full throttle
.
The clutch disc will rotate one turn when
it slips for 3.5 - 4.0 seconds.
3) Repeat Step 2) 20 - 25 times at three minutes intervals.
*
Precautions
a) If the clutch housing temperature
exceeds 5OC, stop the breaking-in operation until it cools down to the normal
temperature.
b) If the clutch stops slipping during the
operation, add one shim of 0.2 mm to
make the clutch slip.
4) Adjust again to the slippage limit point.
*
Wait for the clutch housing to cool down
to the normal temperature
before adjusting.
CLUTCH
5.
Cover
I
F23501405
\I
F23501406
i)
[Order of tightening bolts]
Shim thickness
(Slipoaae
limit
(Alien
to this
thickness)
Shim
Shim
does
thickness
not slip
F23501407
that
slips
Point)
shim
thickness
that
TWG00243
20-37
TESTING
AND ADJUSTING
ADJUSTING
CLUTCH

Testing
1. Remove bolt (I), then remove cover (2).
2. To prevent the circle from rotating, push the
blade against the ground and raise the front
wheels or secure the ends of the blade.
.
Method of raising front wheels
I)
Lower the work equipment to the ground,
then extend the blade lift cylinder further to jack up the front wheels.
2) Apply the parking brake.
Put a block under the frame at the center
of the front axle.
3. Operate the circle rotation lever and check that
the clutch slips.
.
When it starts to slip, there will be a sliding
noise and the holder at the tip of the shaft
will rotate. After checking, return the circle
rotation lever to the neutral position.
However, if the slippage stops immediately,
judge that it is not slipping.
Front
wheels
raised
off
eround
TWG00300
Adjusting
t
Adjust the pushing force of belleville spring (6)
by adjusting the number of shims (5).
INCREASE shims to DECREASE pushing force
and make it EASY to slip
DECREASE shims to INCREASE pushing force
and make it DIFFICULT to slip
1.
When clutch does not slit,

1) Remove bolt (3), thenremove holder (4) and
add shim (5) of 0.2 mm.
2) Install holder (4), then tighten bolt (3).
w
Mounting bolt :
110.5 f 12.5 Nm Ill.25
f 1.25 kgm)
3) Repeat the testing procedure to check if the
clutch slips.
4) Repeat steps I) to 3) until the clutch slips to
align to the slippage limit point.
5) When the clutch slips, remove shim (5) of
0.2 mm.
Set to the shim thickness
where the
clutch does not slip.
Edae
of
blade
held
in
position
TWG00301
I +
Shim
thickness
(Slivvaae
Ilmlt
that
Point)
slips
Chim
20-38
0
Shim
(Al
thickness
ian to this
that
shim
does
not
thickness)
thickness
SIIP
TWG00302
I
TESTING
2.
AND ADJUSTING
ADJUSTING
When clutch slips

1) Remove bolt (3), then remove holder (4) and
take out shim (5) of 0.2 mm.
2) Install holder (4), then tighten bolt (3).
w
Mounting bolt :
110.5 + 12.5 Nm ill.25
k 1.25 kgm1
3) Repeat the testing procedure to check if the
clutch slips.
4) Repeat steps I) to 3) until the clutch slips to
align to the slippage limit point.
5) When the clutch slips, remove shim (5) of
0.2 mm.
.
Set to the shim thickness
where the
clutch does not slip.
Shim thickness
(SliPPage
limit
CLUTCH
that
slips
Paint)
0.2mm
Chim
Shim thickness
(Alien
to this
that
shim
does not
thickness)
thickness
slip
TWG00302
Breaking in clutch
When the clutch disc is replaced with a new
part, break in the clutch as follows.
1) Adjust in Steps 1 and 2 above to align to the
slippage limit point.
2) Make the clutch slip for 3.5 - 4.0 seconds.
.
Run the engine at full throttle
.
The clutch disc will rotate one turn when it
slips for 3.5 - 4.0 seconds.
3) Repeat Step 2) 20 - 25 times at three minutes
intervals.
*
Precautions
exceeds
a) If the clutch housing temperature
5OC, stop the breaking-in operation until it
cools down to the normal temperature.
b) If the clutch stops slipping during the operation, add one shim of 0.2 mm to make the
clutch slip.
z
z
2
4)
5)
Wait for clutch to cool down to normal temperature.

Adjust again to the slippage limit point.
.
Set to shim thickness that does not slip
20-39
0
TESTING
ADJUSTING
AND ADJUSTING
ADJUSTING CLEARANCE
F AND R SWITCHES
Adjusting
1. Set the shift lever to the neutral
operate to the REVERSE position.
CLEARANCE
OF F AND R SWITCHES
OF
position
and
2.
Change the tightening position of nut (I) to adjust the clearance between shift lever plate (2)
and R switch (3).
*
Clearance : 2 mm
3.
Set the shift lever to the neutral position

operate to the FORWARD position.
4.
Change the tightening position of nut (I) to adjust the clearance between shift lever plate (2)
and R switch (4).
*
Clearance : 2 mm
and
4
Checking actuation
.
Check that the LEDs in the F switch and R switch
light up when the switch is ON.
Turn the starting switch on and check that the F
switch (R switch) LED lights up when the shift
lever is operated to the F (RI position.
II
20-40
0
TWG00255
ADJUSTING SHIFT POTENTIOMETER
ADJUSTING SHIFT
POTENTIOMETER
023502
Serial No.: 12013 12015, 12019 12098
20-41
(6)
TESTING
AND ADJUSTING
ADJUSTING
Serial
ADJUSTING
INCHING
No.: 12013 - 12015,
INCHING
POTENTIOMETER
POTENTIOMETER
12019 and up
Transmission control valve

\
From inchina Pedal
Adjust
the output
voltage
of the inching
potentiometer
by adjusting the mounting angle
of potentiometer
(2).
1.
2.
3.
Remove cover (I).

Insert a T-adapter into connector TM1 1.
Turn the starting switch ON and adjust the voltage between terminals @ and @ of TMII.
.
Adjust with the inching pedal not pressed.
Voltage: 0.53 f 0.08 V
.
The voltage can be changed by loosening
screw (3) and changing the mounting angle
of potentiometer
(2).
&
Portion A of potentiometer
(2): LM-G
Turn the starting switch OFF and remove the Tadapter.
.
Connect connector TM1 1 to its original position.
Reset the controller (0 drift).
1) Turn the starting switch ON.
2) Ground the OD terminal inside the right console box to the chassis.
4.
5.
20-42
0
TWG00303
TWG00260
ADJUSTING
MONITOR
The
SPEEDOMETER
speedometer
common
model,
part
the
on
for
the
input
signal
different,
so it is necessary
to match
the model.
Adjustment
Remove
machine
all models,
but
for
monitor
depending
the
to adjust
MODULE
travel
is
OF MACHINE
on the
speed
is
the speedometer
procedure
the machine
monitor,
and adjust
at the back
of the speedometer.
1.
Remove
rubber
caps
II and Ill at the back
of the
speedometer.
2.
When
the
switch
be
of
the
number
switch
rubber
can
with
the table
caps
seen
are
removed,
a rotary
inside.
Check
the
part
speedometer,
then
turn
this
a screwdriver
to adjust
as shown
in
below.
(Part No. 7831-85-6000)
3.
Switch11
Switch
121213131E
After
III
completing
securely
adjustment,
and install the machine
7
Screwdriver
fit the rubber
423F336
caps
monitor.
423F337
20-43
0
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20- 46
Sequence of events in troubleshooting ............................................................................................. 20- 47
Handling of electric equipment and hydraulic component ............................................................. 20- 48
Checks before troubleshooting ........................................................................................................... 20- 56
Electrical circuit system diagram ........................................................................................................ 20- 57
Connector types and mounting locations ....................................................................................... 20-60-49
Electrical wiring diagram .................................................................................................................. 20-60-60
Connection table for connector pin numbers ................................................................................ 20-60-63
T-branch box and T-branch adapter table ........................................................................................ 20-60-99
Method of using troubleshooting charts ...................................................................................... 20-60-102
Details of troubleshooting and troubleshooting procedure ....................................................... 20-60-104
Troubleshooting of engine (S mode) ................................................................................................. 20- 61
023502
Troubleshooting chart for electronic vehicle monitoring system (M mode) ................................. 20- 81
Troubleshooting chart for electronic (engine, parking brake,
transmission control) (E mode) ..................................................................................................... 20-101
Troubleshooting chart for transmission controller (ET mode) ......................................................... 20-151
Troubleshooting chart for hydraulic system (H mode) ..................................................................... 20-201
20-45
(5)
2
POINTS
TROUBLESHOOTING
POINTS TO REMEMBER
a
Stop the machine
AL
When
carrying
allow
a
in a level
If the radiator
Be extremely
When
disconnecting
When
removing
careful
the internal
The aim
prevent
When
wiring,
first.
of troubleshooting
reoccurrence
of possible
carrying
keep
the negative
which
the
basic
and important
troubleshooting
of the failure
have
cause
that
would
point
produce
no connection
with
the reported
to find
a waste
reason,
when
carrying
to carry
the
5)
parts,
will
Check
the stroke
maintenance
4.
or
5.
in
the machine
with
suddenly,
what
conditions
repairs
were
these
same
kind
of failure
Check the oil level

the piping
20-46
0
any
external
or hydraulic
Check the travel
to reenact
do
not
or measureworse.
investigation
2 - 4 to narrow
then
to
and
in-
down
the
use the troubleshoot-
locate
the
position
of the
exactly.
The basic
procedure
for troubleshooting
Start
from
the simple
Start
from
the most
3)
Investigate
the
occurred
6.
Measures
to remove
Even if the failure

of the failure
be-
will
occur
cause.
of oil from
equipment.
levers.
other
points.
likely
related
points.
parts
or in-
formation.
occur?
problem
of the control
of the
1)
out?
leakage
of op-
symptoms,
2)
troubleshooting
Check
the machine
investigation
of failure,
flowchart
To prevent
1)
yourself,
it as a real fail-
the method
there
out before
carried
failure
before
or were
condition
carried
repairs
2)
3)
ex-
is considered
may make the problem
in Items
ma-
for
spool.
is as follows.
did the failure
been
out any
results
failure
the
with
operating
Use the
ing
apart from
about
of the
to handle
troubleshooting
spection
occurred?
occur
before
valve
Troubleshooting
reported?
strange
the failure
When
causes
occurred
problems
Check
idea
etc.
the
procedure.
has been
anything
before
Has the
some
can be checked
any item that
whether
ment that
prior
fore?
3.
so check
carry
failure?
6)
and to
and function.
to form
items
ure or as a problem
out troubleshoot-
Did the failure
When
release
swiftly,
of the control
Confirming
failure
.
Confirm
the extent
also lose
out thorough
problems
that
there
Had any
repairs
the structure
Other
to ask user or operator
Have any other
Under
for
symptoms.
this?
4)
or air, always
questions
4)
cause
out troubleshooting
the fixed
the problem
3)
various
ternally,
be disas-
of manhours,
and to carry
with
chine
so wait
it properly.
out
to understand
of the user or operator.
it is necessary
Was
oil, water,
to carry
eration,
and at the same time,
investigation
2)
from
5)
any
the fail-
parts will
impossible
also cause
the confidence
1)
burns,
first.
be sure to connect
is of course
do not hurry
immediately
unnecessary
become
oil or grease,
Points
pressure
is to ask the operator
of the failure.
2.
and do not
parts.
of the battery
and judge
accordance
signals,
fitted.
to be necessary.
ure or other
For this
are securely
out and cause
rotating
of the failure,
sembled.
ing,
in any
equipment,
the components.
failure occurs:
.
Parts that
It will
to the agreed
(-) terminal
is under
measuring
is to pinpoint
are disassembled
It will
strictly
brake
of the failure.
If components
and parking
may spurt
or to get caught
a location
out troubleshooting,
to disassemble
hot parts
installing
cut to effective
causes
workers,
is hot, hot water
disconnect
a short
pin, blocks,
troubleshooting.
any
When
or more
the engine
always
TROUBLESHOOTING
near.
starting
the plug or cap from
carrying
When
when
before
not to touch
pressure
However,
1.
down
two
to come
cap is removed
to cool
with
person
WHEN
WHEN TROUBLESHOOTING
and check that the safety
out the operation
any unauthorized
the engine
place,
TO REMEMBER
root
cause
is repaired,
is not repaired,
of failure
if the root cause
the same failure
again.
this,
occurred.
always
Then,
investigate
remove
why
the
the
root
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
Office, shop
eP 1
IExamination,
1)
When
confirmation
a request
21
repairs
&Q
TFWIIII(I
Jobsite
is received,
first
,,
II
points.
Name
of customer
Type,
serial
Details
R ins!
number
of jobsite,
Ask questions
RO
of symptoms
for
ask the following
TFWnOl
Ring!
of machine
etc.
to gain an outline
of the prob-
Ien%
-
Condition
Work
of failure
being
carried
out at the time
TEW00182
of the
failure
.
Operating
Past history,
eP 2
Determining
1)
environment
details
of maintenance,
etc.
TEP01348
probable
Look
at the
shop
manual
location
of cause
troubleshooting
to
find
section
locations
of
of the
possible
causes.
*
2)
Hydraulic
Look
essary
pressure
in the parts
replacement
book
gauge
end
Decide
kit, etc.
prepare
1 Repair
at
action
to take
/ )
jobsite
the necBefore
parts.
repair
2)
starting
simple
troubleshooting,
Check
before
Other
check
and
starting
select
items
items
See the Troubleshooting

manual,
locate
failures.
Section
of the shop
a troubleshooting
flowchart
Step 6
&-enacting
Drive
the
failure]
and
operate
condition
and
the
judge
machine
if there
to confirm
is really
failure.
TEP01351
Was there
chine
anything
before
Did the failure

TEWOOlB9
Had any repairs

failure?
strange
the failure
occur
about
the
ma-
out before
the
occurred?
suddenly?
been carried
TEWOOl91
20-47
0
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
2.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
20-48
(5)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
023502
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5)
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
023502
3)
20-49
(5)
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q
20-50
(5)
When removing from clips

Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3]
Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
023502
3.
023502
2)
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
20-51
(5)
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
Disconnection
Connection (Example of
incomplete setting of (a))
023502
3)
20-52
(5)
023502
4)
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
20-53
(5)
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
20-54
(5)
023502
4.
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
023502
1.
20-55
(5)
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
023502
5.
20-55-1
(5)
Electrical
check
components
Other
023502
items
A
A
A
compoetS
Hydraulic.
mechamcal
Item
Electrical
equipment
Lubricating
Checks
P
0
13 .
water
starting
oil, cooling
before
TROUBLESHOOTING
ELECTRICAL
ELECTRICAL CIRCUIT SYSTEM
CIRCUIT
SYSTEM
DIAGRAM
DIAGRAM

SYSTEM
Serial No.: 11001 - 12012, 12016 - 12018
Final drive oil

wllperature
sensor
Engine oil
pressure switch
[r/i
iii/i1
IF
Radiator water
level sensor
II/l
Hydraulic oil level sensor
CN PL
DIFF
+-.--J&
(Right)
e *ensor
Accumulator
Fl0a1
(Left
Parking
To flasher relay
Warning
To turn signal lamp

To head lamp
II
lllll
Startina
watertemperature
62
I ST
Electrical Intake
Head lamp Hi-Low
---
,-,
235FO2079
20-57
0
ELECTRICAL
TROUBLESHOOTING
CIRCUIT
SYSTEM
DIAGRAM
Y
PleSSle
switch
w/Electrical
air
Head Iaav
snitch
Winker
(2OW)
Starting
motor
Winker
125W)
Parking
13W)
Winker
(25W)
Parking
(3Wl
intake
heater
Alternator
TWG00345
20-59
0
TROUBLESHOOTING
ELECTRICAL
TRANSMISSION
CONTROL
Serial No.: 11001 - 11030
(l)The
Procedure
connectors
SYSTEM
DIAGRAM
SYSTEM
Body
PROCEDURE
GEARSHIFT
CIRCUIT
1Transmission
control
box
Proximity
switch(F)
Proximity
switch(R1
(XtYPe)
IXtYPe)
assy
Relay
(Starting
FOR
TESTING
SIGNALS
is
for
as
connecting
in
shown
below.
to
the
GND
lWG00244
20-60
0
TROUBLESHOOTING
Relay
(BAck-uD
buzzer)
ELECTRICAL
Relay
(Diffe-
Relay
rent lall
(RI
CIRCUIT
SYSTEM
DIAGRAM
Relav(F)
Print
board
circus
CN-TO
Rotary
switch
Diode
(3lThe
in
(2)Connect
specifications
load
and
q
q
q
q
q
the
pi
siana
iBack-uo
:Startina
lot
lamp
check
1 to
actuation
the
table
is
as
below.
shown
(24V
each
buzzer
motor
iDifferential
lock
LTransmission
clutch
solenoid
:Transmisslon
clutch
solenoid
solenoid
on
4th
clutch
so
enoid
on
3th
clutch
so
enold
on
2th
clutch
so
enoid
on
lth
clutch
so
enoid
on
low
clutch
so
on
hIat
clutch
enoid
s 0 lenoid
TWG00245
20-60- 1
0
TROUBLESHOOTING
ELECTRICAL
Serial No.: 11031 - 12012,
SYSTEM
DIAGRAM
12016 - 12018
Body
Transmission
-.._._-__-__-.._-.-._-___
CIRCUIT
solenoid
1 Transmission
I
control
box
assy
valve
2nd
4th
1st
LO
Hi
3rd
F
R
PROCEDURE
GEARSHIFT
FOR
TESTING
SIGNALS
(lIThe
Procedure
connectors
Power
drivino
switch
difierkniiai
source
rotary
relay
is
for
as
connecting
shown
in
below.
to
the
for
lock
1 +14v 1
TWG00246
20-60-2
0
TROUBLESHOOTING
Relay
Relay
(BAck-ue
buzzer)
(Differential)
ELECTRICAL
CIRCUIT
DIAGRAM
Relay
Relar(R)
(Parking
brake)
Relay(F)
int
board
CN-TO
I
(SWP
type1
circuit
! p
(2)
SYSTEM
q
q
q
q
r-Y
sxich
ISIP type1
P
-m
Diode
Connec t
specif
~oao
0. 68rR
Rotary
the
Pilot
icationsi
and
sianal.
: Parking
lamp
: Parking
brake
iBack
lamp
to
check
(3)The
in
(24V
actuation
the
table
is
as
below.
shown
each
buzzer
;Startino
motor
:Different
al
lock
;Transmlss
on
clutch
solenoid
;Transmlss
on
clutch
solenoid
:Transmiss
on
4th
clutch
solenoid
:Transmiss
on
3th
clutch
solenoid
:Transmiss
on
2th
clutch
solenoid
:Transmiss
on
Ith
clutch
solenoid
clutch
solenoid
:Transmiss
on
low
:Transmlss
on
hioh
solenoid
clutch
solenoid
TWG00247
20-60-3
023502
a-n
-a
:a
--m
3m
:;I:
memo,~
drift
CN-SWR
------1
CN-SWF
reset
CN-FRError
TROUBLESHOOTING
ELECTRICAL
CIRCUIT
SYSTEM
DIAGRAM
(2/2)
Procedure
(l)The
for testing
Procedure
connectors
is
gearshift
for
as
signals
connecting
to
in
below.
shown
Power
sollrce
for
rIlg
relay
far
clutch
+24v
Power
back-up
SoUrce
for
buzzer
+24V
Power
startlna
source
for
motor
+24V
Power
source
differential
Power
source
transmission
solenoid
the
Transmission
cant
rol
box
ass
for
lock
1 CN-E2
+24V
Transmission
controller
----v
Ground
(2)
nect
the
oi
cificationsl
d and
signal.
iParking
(24V
eat
:3)
h
The
in
actuation
the
table
is
below.
as
shown
brake
buzzer
:Starting
20-60-6
0
lamp
check
lamp
:Parkino
:Back
IO t
to
mot0
iDifferential
lock
solenoid
:Transmission
R clutch
sole
:Transmission
sole
;Transmission
4th
clutch
so lenoid
:Transmission
3th
clutch
so lenoid
:Transmission
2th
clutch
so lenoid
;Transmission
lth
clutch
so lenoid
:Transmission
low
clutch
so lenaid
iTransmission
hioh
clutch
clutch
noid
naid
s olenoid
TWG00306
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
CONNECTOR
Connector
No.
TYPES AND MOUNTING

1Connectortype 1No. of pins 1
LOCATIONS
LOCATIONS
Mounting
1 Address
location
CNl
SWP
Intermediate
connector
(articulate
section)
F9, A4
CN2
Intermediate
connector
(articulate
section)
F7, A3
CN3
Intermediate
connector
(below
left side of floor
frame)
12
CN4
SWP
12
Intermediate
connector
(below
left side of floor
frame)
I2
CN5
SWP
14
Intermediate
connector
(below
left side of floor
frame)
HI
1 CN6
1 KES2
1 Intermediate
connector
(inside
of R.H. console
1 CN7
12
I Intermediate
connector
(left side of radiator)
SWP
box)
CN8
SWP
16
Intermediate
connector
(inside
of R.H. console
box)
CN9
SWP
12
Intermediate
connector
(inside
of R.H. console
box)
CNIO
Relay
Engine
oil pressure
CNII
Buzzer
(inside
1 CN12
1 CN13
CN14
of R.H. console
connector
connector
(below
left side of floor
1 I ntermediate
connector
(inside
of R.H. console
connector
(next
SWP
G2
G2
Intermediate
1 E2, J7
box)
I Intermediate
swp
H4
/ G3, J3
relay
I2
frame)
box)
Gl
D2
SWP
12
Intermediate
CN16
KESl
Monitor
module
CN17
DLI
Monitor
module
module
CN19
DLI
12
1 Monitor
MIC
I Speedometer
module
16
Speedometer
module
CN21
Intermediate
connector
(below
CN22
Intermediate
connector
(next
CN23
Intermediate
connector
14
I Intermediate
connector
1 CN26
CN27
SWP
12
I Intermediate
connector
(below
SWP
16
I Intermediate
connector
(below
KESI
Head
lamp
CN29
YPC
Cab mount
CN30
SWP
Speed
CN31
Final
I Engine
I Fuel gauge
CN32
CN33
I
I
Hi-Lo
frame)
HI
left side of floor
frame)
HI
left side of floor
frame)
G2
left side of floor
I4
switch
switch
oil pressure
Engine
water
Engine
oil level
switch
temperature
CN36
Hydraulic
K7
sensor
sensor
J6
J7
sensor
J9
sensor
oil level
J5
switch
L6
/ Air pressure
switch
(L.H.)
1 H9, K6
switch
(R.H.)
19, K6
D2
CN38
I Air pressure
CN39
KESI
/ Ra dla t or coolant
CN41
c2
82, G7, 01
CN40
J4
to L.H. battery)
oil temperature
CN34
panel)
sensor
drive
CN35
CN37
monitor
(below
selector
lamp
KESI
YPC
3
6
Turn
signal
Hazard
level
switch
switch
(OPT)
H4
SWP
CN28
DLI
/ CN25
to L.H. battery)
]~~~:I
CN20
1A4. G9. 14.M51
CN15
I CN18
sensor
I5
-
20-60-7
0
CONNECTOR TYPES AND MOUNTING LOCATIONS
023502
Serial No.: 12019 12502
20-60-52
(6)
023502
Connector No.
Connector type No. of pins
Mounting location
Address
CN1
DT-T
Intermediate connector (articulate section)
F9, A4
CN2
DT-T
Intermediate connector (articulate section)
F7, A3
CN3
DT-T
12
Intermediate connector (below left side of floor frame)
H1
CN4
DT-T
H1
CN5
DT-T
12
H2
CN6
KES2
Intermediate connector (inside of R.H. console box)
G3, J3
CN7
DT-T
12
Intermediate connector (left side of radiator)
E2, J7
CN8
SWP
16
G2
CN9
SWP
12
G2
CN10
Relay
Engine oil pressure relay
H4
CN11
Buzzer (inside of R.H. console box)
CN12
Intermediate connector
CN13
DT-T
G2
CN14
DT-T
CN15
SWP
12
Intermediate connector (next to L.H. battery)
D2
CN16
KES1
Monitor module
CN17
DLI
Monitor module
CN18
DLI
12
Monitor module
CN19
MIC
Speedometer module
CN20
DLI
16
Speedometer module
CN21
Intermediate connector (below monitor panel)
J4
CN22
DT-T
Intermediate connector (next to L.H. battery)
C2
CN23
Intermediate connector
H4
CN25
DT-T
12
H1
CN26
DT-T
12
I3
CN27
DT-T
J2
CN27A
DT-T
I1
CN28
KES1
Head lamp Hi-Lo selector switch
I4
CN29
YPC
Cab mount lamp switch
CN30
SWP
Speed sensor
CN31
Final drive oil temperature sensor
K7
CN32
Engine oil pressure switch
J6
CN33
Fuel gauge sensor
J7
CN34
Engine water temperature sensor
J9
CN35
Engine oil level sensor
J5
CN36
Hydraulic oil level switch
L6
CN37
Air pressure switch (L.H.)
H9, K6
CN38
Air pressure switch (R.H.)
I9, K6
CN39
KES1
Radiator coolant level sensor
D2
CN40
KES1
Turn signal switch
I5
A4, G9, I4, M5
B2, G7, O1
20-60-55
(6)
Connector No.
Mounting location
Address
CN41
YPC
Hazard switch (OPT)
CN43
CN46
CN50
Intermediate connector (rear of operators seat)
K4
CN51
SWP
Engine stop motor
D5
CN52
DT-T
H2
CN53 (inside of R.H. console box)
Relay
Engine stop motor relay
CN53 (hydraulic oil tank)
Hydraulic oil temperature sensor
L6
CN55
DT-T
G1
CN56
Back-up alarm
CN57
KES0
Rear combination lamp (L.H.)
CN58
KES0
Rear combination lamp (R.H.)
CN59
Rear work lamp
CN61
Relay
Emergency steering relay
H4
CN63
H2
CN64
KES2
ESC (emergency steering) (inside of R.H. console box)
CN65
KES2
ESC (emergency steering) (inside of R.H. console box)
CN66
H4
CN67
DT-T
CN67A
DT-T
I2, N2
CN67B
DT-T
I1, N2
CN68
Pressure switch (emergency steering)
H1
CN69
Rear work lamp
CN71
KES2
Differential lock solenoid
K7
CN73
KES2
Parking brake solenoid
B5
CN74
Air drier
CN77
Starting switch
CN79
SWP
16
Intermediate connector (rear of operators seat)
K4
CN82
KES0
Air pressure sensor
L5
CN86
R.H. sensor (blade float) (blade lift lever)
CN87
L.H. sensor (blade float) (blade lift lever)
CN88
Intermediate connector (blade float) (below left side of floor frame)
CN89
Relay
Blade float relay (R.H.)
CN90
Relay
Blade float relay (L.H.)
CN91
DT-T
J2
CN93
DT-T
J1
CNA7
Intermediate connector (below air tank)
CNA28
Intermediate connector (below air tank)
CNAC
Air conditioner compressor
CNAG
YPC
Air gauge
20-60-56
(6)
H4, K6
G9, K5
023502
023502
Connector No.
Mounting location
Address
CNE1
MIC
13
CNE2
MIC
21
CNE3 (No.1 20)
AMP040
20
CNE3 (No.21 36)
AMP040
16
CNE4
AMP040
12
CNE5
MIC
17
CNFBW
YPC
Blade work lamp switch
CNFR
Error memory reset (inside of R.H. console box)
M3
CNFW
YPC
Front work lamp switch
CNOD
0 drift (inside of R.H. console box)
M2
CNPL
KES0
Pilot lamp
CNPL
Panel lamp
J4
CNRBB
Relay
Back-up buzzer relay
M8
CNRCB
Relay
Caution buzzer relay
P8
CNRDI
Relay
Differential lock relay
N8
CNRIL
Relay
Tail lamp (not used)
O9
CNRPB
Relay
Parking brake relay
G4
CNRPST
Relay
Starting motor relay
G4
CNRST
Relay
Starting motor relay
M7
CNRW
YPC
Rear work lamp switch
CNSM
Service meter
CNST
AMP
Starting motor
I7
CNSWF
F switch
M5
CNSWR
R switch
M6
CNT03
SWP
12
Transmission control switch
CNTM3
For flash memory write (transmission controller)
CNTM4
Shift potentiometer 1
M7
CNTM5
Shift potentiometer 2
N8
CNTM9
SWP
Engine speed sensor
R7
CNTM10
SWP
Transmission oil temperature senor
R3
CNTM11
R6
CNTM13
DT-T
12
M5
CNTM14
DT-T
12
M4
CNTM15
DT-T
12
Intermediate connector (below left of air tank installation table)
R4
CNTM16
DT-T
12
Intermediate connector (below left of air tank installation table)
R4
CNTM95
DT-T
Intermediate connector (engine speed sensor)
R5
CNTMC
N2
E5
Intermediate connector (slow below fuse fuse box)
G2
E6
Intermediate connector (slow below fuse fuse box)
G2
20-60-57
(6)
023502
ELECTRICAL WIRING DIAGRAM (1/3)
20-60-59
(6)
(2/3)
023502
Serial No.: 11001 12502
20-60-60
(6)
(2/3)
023502
20-60-61
(6)
023502
(3/3)
20-60-62
(6)
Connection table for connector pin numbers

a
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
20-60 (7)
63
20-60 (7)
64
20-60 (7)
65
20-60 (7)
66
20-60 (7)
67
20-60 (7)
68
20-60 (7)
69
20-60 (7)
70
20-60 (7)
71
20-60 (7)
72
20-60 (7)
73
20-60 (7)
74
20-60 (7)
75
20-60 (7)
76
20-60 (7)
77
20-60 (7)
78
20-60 (7)
79
20-60 (7)
80
20-60 (7)
81
20-60 (7)
82
20-60 (7)
83
20-60 (7)
84
20-60 (7)
85
20-60 (7)
86
20-60 (7)
87
20-60 (7)
88
20-60 (7)
89
20-60 (7)
90
20-60 (7)
91
20-60 (7)
92
20-60 (7)
93
20-60 (7)
94
20-60 (7)
95
20-60 (7)
96
20-60 (7)
97
20-60 (7)
98
T- branch box and T- branch adapter table
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
(Rev. 2009.03)1
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
799-601-2710 Adapter for MIC
MIC-5P
q q
13
MIC-13P
q q
799-601-3470 Case
17
MIC-17P
q q q
q q
21
MIC-21P
q q q
q q
MIC-9P
q q q
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
799-601-4350 T-box (for DRC 60, ECONO)
799-601-2850 Case
60
799-601-4360 Case
q
X2P
q q q
X3P
q q q
X4P
q q q
SW6P
q q q
q q q
799-601-7010 Adapter for X (T-adapter)
799-601-7020 Adapter for X

799-601-7050 Adapter for SWP
SW8P
12
SW12P
14
SW14P
16
SW16P
q
q
q
q
799-601-7080 Adapter for M (T-adapter)
799-601-7090 Adapter for M
M2P
q q q
M3P
q q q
20-60 (7)
99
S8P
q q q
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
q q q
16
S16P
16
S16PW
12
S12PW
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-7140 Adapter for S
799-601-7170 Adapter for S (Blue)
799-601-9100
M8P
799-601-9000
799-601-8000
q
799-601-7500
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
q
799-601-7180 Adapter for AMP040
A8P
12
A12P
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
799-601-9020 Adapter for DT
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (Gray)
DT8GR
799-601-9070 Adapter for DT (Black)
DT8B
799-601-9080 Adapter for DT (Green)
DT8G
799-601-9090 Adapter for DT (Brown)
DT8BR
799-601-9110 Adapter for DT (Gray)
12
DT12GR
799-601-9120 Adapter for DT (Black)
12
DT12B
799-601-9130 Adapter for DT (Green)
12
DT12G
799-601-9140 Adapter for DT (Brown)
12
DT12BR
799-601-9210 Adapter for HD30-18
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)

799-601-9320 T-box (for ECONO)
20-60 (7)
100
24
q q
q q
q q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
799-601-2700
Identification
symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
799-601-9330 Case
799-601-9340 Case
799-601-9350 Adapter for DRC
40
DRC-40
q
q
799-601-9360 Adapter for DRC
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)

799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
A3
q q
q q
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q

799-601-4140
Atomosphere pressure
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
FCIB
q q

799-601-4160
Oil pressure switch
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2)

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM
799-601-4190*

Commonrail pressure
1,2,3L
q q
799-601-4230*

Air intake pressure/temperature
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q
q q
799-601-4340*

Pump actuator
2,PA
799-601-4380*
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
1,2,3,4T
q
q q
799-601-4260 Adapter for controller (ENG)
DTP4
50
DRC50
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.
20-60 - 101
(7)
TROUBLESHOOTING
OF ENGINE
(S MODE)
S-l
s-2
Starting
performance
is poor (Starting
Engine
does not start
Engine
does not turn
Engine
turns
Exhaust
gas comes
out but engine
s-3
Engine
does not pick up smoothly
s-4
Engine
stops
s-5
Engine
does not rotate
S-6
Engine
lacks output
s-7
Exhaust
S-8
Oil consumption
s-9
Oil becomes
s-10
Fuel consumption
S-l 1
Oil is in cooling
s-12
Oil pressure
S-l 3
Oil level rises
s-14
Water
S-l 5
Abnormal
S-l 6
Vibration
during
operations
(hunting)
contaminated
is poor)
injected)
(or exhaust
20-64
20-65
....................................................................
quickly
is excessive
or water
................................................................................
gas is blue)
.....................................................................
noise is made
is excessive
20-67
20-68
20-69
20-70
20-71
......................................................................................................
20-73
spurts
20-74
back, or water
up (drop in oil pressure)
becomes
20-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
level goes down
............................................
...........................................................................
...............................................................................................................................
temperature
20-63
...................................
injected)
....................................................................................
combustion)
20-62
.....................................
.....................................................................................................
gas is black (incomplete

is excessive
out (Fuel is not being
.....................................................................................................
(no power)
lamp lights
..............................................................
does not start (Fuel is being
(Follow-up
smoothly
water,
takes time)
..............................................................................................................
but no exhaust
gas comes
always
too high (overheating)
.......................................................................
...............................................................................................................
...................................................................................................................
20-75
20-76
20-77
20-78
20-79
20-61
0
TROUBLESHOOTING
S-l
Starting
General
performance
TABLE
is poor (Starting always takes time)
causes why starting performance
is poor
- Defective electrical system

- Insufficient supply of fuel
- Insufficient intake of air
f Improper
selection of fuel
(At ambient
ASTM
temperature
Legend
of -10C
D975 No. 1, and -10C
or below,
use
or above, use ASTM
The
Battery charging
specific
gravity
of 70% in the above
. In cold
charging
weather
Possible
:
:
causes
probable
Possible
Items
(judging
causes
causes
from
due to length
to confirm
Questions
(judging
from
and check
Questions
of use (used
exceed
the value
for the charging
for a long
the cause.
rate
table.
the specific
gravity
must
exceed
the value
for the
table.
measured.
it IS found to be
IoIo/
items)
and Check
rate.
rate of 75% in the above
20-62
should
Q : Most
0
D975 No. 2 diesel fuel.)

t
items1
period)
S-2 Engine does not start

0 Engine does not turn
General
causes why
. internal
*
engine
parts of engine
If internal
does not turn

seized
parts of the engine are seized, carry
out troubleshooting
for Engine
stops during
operations.
. Failure in power train

. Defective electrical system
Legend
:
:
:
: Items
0
G
Possible
Most
causes
probable
Possible
(judging
causes
causes
to confirm
due to length
IS turned
turned
to START,
moves
out, but
from
and check
Questions
of use (used
items]
and Check
for a long
items)
period)
ON
the cord,
1) When
Questions
the cause.
switch
connect
from
(judging
terminal
pinion
and carry
out troubleshooting
B and terminal
C of starting
at ON
switch
are connected,
20-63
@ Engine turns but no exhaust
gas comes out
(Fuel is not being injected)

General
comes
causes why engine turns but no exhaust
. Supply of fuel impossible

f Supply of fuel is extremely small
. Improper selection of fuel (particularly
Standards
of fuel
Diesel
-22
-4
-30
-20
in winter)
for use of fuel

Ambient
Type
gas
out
,4
-10
temperature
32
50
68
86
104
122F
10
20
30
40
50C
fuel
Legend
0
6,:)
: Possible causes (judging from

: Most probable causes (judging
A : Possible
0
: Items
causes
to confirm
1 Confirm
20-64
due to length
Questions
from
and check
Questions
of use (used
items1
and Check
for a long
items)
period)
the cause.
recent
reoair
historv
Exhaust
gas comes
out
but engine
does
not
out
but
start
(Fuel is being injected)
General
engine
causes
why
exhaust
gas
comes
does not start
. Lack of rotating
force
due
to defective
electri-
cal system
. Insufficient supply of fuel

. Insufficient intake of air
. Improper selection of fuel
Legend
0
0
A
:
:
:
Possible
Most
causes
probable
Possible
causes
l : Items to confirm
When
(judging
causes
from
(judging
due to length
Ouestions
from
and check
Questions
of use (used
and
for a long
the cause.
fuel filter
is drained,
no fuel comes
out
items)
Check
items)
period)
S-3 Engine does not pick up smoothly
(Follow-up
is poor)
General causes why engine does not pick up smoothly
.
.
*
.
Insufficient
intake of air
insufficient
supply of fuel
Improper
condition of fuel injection
Improper
fuel used
Legend
0
Possible
causes
(judging
from
Questions
length
Replacement
When
exhaust
temperature
20-66
of filters
manifold
of some
of use (used
has not been
is toLched
cvlinders
When
fuel cap is inspected
When
feed
pump
and check
is operated,
items)
for a long
carried
period)
out according
Immediately
after
to operation
starting
IllI
Ill
III
engine,
is low
directly,
it is found
operation
to be clogged
is too light
or too heavy
0
l
S-4 Engine stops during operations

General
causes why
engine
stops
during
operations
. Seized parts inside engine

- Insufficient supply of fuel
. Overheating
*
If
there
is
output,
overheating
carry
out
and
insufficient
troubleshooting
for
over-
heating.
. Failure in power train

*
If the
the
engine
power
stops
train,
because
carry
of a failure
out
in
troubleshooting
for the chassis.
:gend
0
a
A
0
:
:
:
:
Possible
Most
Possible
Items
causes
probable
(judging
causes
causes
from
Questions
(judging
from
due to length
to confirm
and check
Questions
of use (used
for a long
items)
period)
the cause.
Confirm
recent
Deoree
of use
repair
history
1 Operated
-_I
Condition
items)
and Check
when
for long
.._:__
period
..^^
.^___I
engine
stopped
Non-specified
When
feed
Mud
is stuck
Engine
fuel
pump
Remove
used
there
is no response
or it is heavy
0
d
to fuel tank cap
turns.
Try to turn
is being
is operated,
but stops
by hand
head cover
transmission
control
lever
is
using
and check
When
qear train
Turns
when
When
fuel filter,,strainer
pump
when
is inspected,
auxiliary
directly
it does
not tL
equipment
is removed
are inspected
directly,
they
is inspected
directly,
it is found
t-1
are found
1
2
to be clogged
When
feed
pump
strainer
to be clogged
Check feed
When
does
pump
control
not return
directly
rack is pushed,
it is found
to be heavy
or
/I
III
III
III
20-67
S-5 Engine does not rotate smoothly (hunting)

General
causes why
. Air in fuel system

. Defective governor
. Defective
electric
governor
*
does not rotate
smoothly
mechanism
goyernor
machanism
(electric
type)
If there
rod
engine
is no hunting
is disconnected,
for the electrical
when
carry
the electric
out
governor
troubleshooting
system.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Condition of hunting
epacemen
20-68
S-6 Engine lacks output (no power)

General
.
.
.
.
causes why engine
Insufficient
lacks output
intake of air
Insufficient
supply
of fuel
Improper
condition
Improper
fuel used
(if non-specified
of fuel injection
fuel is used, output
drops)
. Lack of output due to overheating

*
If
is
there
output,
overheating
carry
out
and
troubleshooting
insufficient
for
over-
heating.
Legend
0
:
:
:
Possible
Most
causes
probable
Possible
cau
Color
(judging
causes
from
(judging
e to length
of exhaust
Questions
from
and check
Questions
of use (used
items)
and Check
for a long
items)
period)
gas
en va ve c earance
IS c
20-69
S-7 Exhaust gas is black (incomplete
combustion)
General causes why exhaust gas is black
. Insufficient intake of air

. improper condition of fuel injection
* Excessive injection of fuel
Legend
0
@
a
0

: Possible causes due to length
: Items to confirm the cause.
Color
of exhaust
Power
was lost
Questions
from
and check
Ouestions
of use (used
and
items)
Check
items)
for a long period)
gas
;
.g
I
Fi
Non-specified
Noise
Dust indicator
Blow-by
is being
used
is heard
from
around
turbocharger
\?
is red
gas is excessive
Engine
pickup
When
exhaust
standard
20-70
fuel
of interference
is poor and combustion

manifold
is touched
is irregular
immediately
0
after
starting
::
engine,
value
When
muffler
is removed,
When
control
rack is pushed,
exhaust
gas color
it is found
returns
to be heavy,
to normal
or does
not return
S-8 Oil consumption is excessive (or exhaust gas is blue)

* Do not run the engine at idling for more than
20
minutes
continuously.
(Both
low
and
high
idling)
General
causes why oil consumption
is excessive
. Abnormal combustion of oil

. External leakage of oil
. Wear of lubrication system
Legend
0
Possible
causes
(judging
from
Questions
and check
gth of use (used
for a long
items)
period)
20-7 1
S-9 Oil becomes contaminated

General
causes
why
oil
quickly
becomes
contaminated
quickly
.
.
.
.
.
Intake
of exhaust
gas due to internal
Clogging
of lubrication
Improper
Improper
combustion
oil used
Operation
under
wear
passage
excessive
load
Legend
0
6
:
:
Possible
Most
A : Possible
0
Items
2
0
causes
probable
(judging
causes
causes
from
Questions
(judging
from
due to length
to confirm
of use (used
items)
and Check
for a long
items)
period)
the cause.
Color
of exhaust
When
oil filter
is inspected,
When
exhaust
pipe
Enoine
and check
Questions
gas
oil temoerature
When
compression
When
breather
metal
is removed,
particles
inside
are found
is found
to be dirty
with
rises auicklv
pressure
UJ
E
:
c
oil
,,,
is measured,
It is found
to be low
;
-0
with
dirty
When
oil filter
When
oil cooler
Excessive
When
is inspected
directly,
it is found
to be clogged
P
G
8
5
oil, or hose is broken
Turbocharger
20-72
element
is inspected
directly.
is inspected
drain
tube
valve
it is found
to be clogged
is directly
__
shaft
inspected,
to be clogged
is cloqqed
play of turbocharger
safety
it is found
directly,
I.1
a
b
I
0
spring
is found
to be catching
%
.
t
&
S-l 0 Fuel consumption

General
is excessive
causes why fuel consumption
. Leakage of fuel
. Improper condition
. Excessive injection
of fuel injection
of fuel
om Questions
Most
probable
A : Possible
Items
ca
causes
ging
is excessive
from
and check
Questions
gth of use (used
items)
and Check
for a long
items)
period)
to confirm
of same
Condition
Injection
Speed
model
of fuel consumption
pump
test shows
of some
cylinders
that
does
injection
amount
not change
when
is excessive
operatjng
on reduced
cyltnders
When
control
When
check
rack is oushed.
IS made
using
it is found
delivery
to be heavv.
method,
injection
or does
timng
not return
is found
to be incorrect
Remove
head cover
and check
directly
Remove
feed
and check
directlv
pump
1.1
/.I
20-73
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General
causes why oil is in cooling
water
* Internal leakage in lubrication system

. Internal leakage in cooling system
LegC!O
ssible
causes
(judging
from
Questions
and check
_____. , _
Oil level
Graduallv
Hard water
,
li
Engine
is being
oil level
used as cooling
has risen.
Excessive
air bubbles
.S
.,
Hvdraulic
oil, torque
When
items)
wilt07
hydraulic
oil is cloudy
inside
radiator,
converter,
oil, torque
white
spurts
back
transmission
converter,
oil is cloudv
transmission
white
I CC?
I I
oil is drained,
ic fn,,nrl
Pressure-tightness
test of oil cooler

test of cylinder
Remove
cylinder
head and check
Remove
011 pan and check
directly
shows
there
head shows
directly
is leakage
there
1s leakage
Cz
Pressure-tightness
20-74
increased
water
S-12
Oil pressure lamp lights up (drop in oil pressure)
General
.
*
*
.
+
causes why oil pressure
lamp lights up
Leakage, clogging, wear of lubricating

Defective
Improper
Deterioration
Standards
Type
of oil
system
oil pressure control

oil used (improper viscosity)
of oil due to overheating
for engine oil selection
Selection
-22
-30
-4
-20
of oil SAE number

according
to ambient
temperature
14
-10
32
0
50
10
68
20
86
30
104
40
I
122F
5oc
!gend

Questions
from
and check
Questions
gth of use (used
Condition
When
m
.s
8
f
There
is inspected
oil pan and check
Oil pump
for a long
items)
period1
oil pressure
when
oil filter
Remove
items)
and Check
rotation
is catching
is heavy,
of relief
directly,
it is found
to be clogged
there
valve
l
0
directly
F
Z
8
f =m
=
+ .e
0
0
is play
or regulator
valve,
spring
or
1_
eB
20-75
S-13 Oil level rises

t If there is oil in the cooling
troubleshooting
General
water,
for Oil is in cooling
causes why
carry
out
water.
oil level rises
. Water in oil (cloudy white)

. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
Legend
20-76
S-14 Water temperature

General
causes
why
becomes too high (overheating)
water
temperature
becomes
too high
. Lack of cooling
water
(deformation,
damage
of
fan)
. Drop in heat dissipation efficiency

. Defective cooling circulation system
. Rise in oil temperature
of power train
*
Carry out troubleshooting
for chassis.
Legend
0
a
:
:
:
:
Possible
Most
causes
probable
Possible
Items
causes
to confirm
Degree
water
from
(judging
due to length
Questions
from
and check.items)
Questions
of use (used
and
for a long
Check
items)
period)
the cause.
1 Operated for long period

E .,A^_,..
^..^_L_^._A
of use
temperature
Temperature
even
(judging
causes
/A IA
0 0
gauge
difference
at the cracking
a 1a
:\-
between
top and bottom
radiator
tanks
is
temperature
20-77
S-l 5 Abnormal noise is made

* Judge if the noise is an internal
external
General
noise
or an
noise.
causes why
abnormal
noise is made
. Abnormality
due to defective
parts
. Abnormal combustion noise
* Air sucked in from intake system
Legend
0
: Possible
Q : Most
A : Possible
0
causes
probable
Items
(judging
causes
causes
from
and check
Questions
of use (used
items)
and Check
for a long
recent
Degree
of use
repair
history
of abnormal
noise
1 Gradual1 y occurred
Suddenly
Non-specified
Engine
fuel
oil must
is being
be added
Color
or exhaust
Metal
particles
Noise
Engine
When
occurred
__._....
more
use d
1-1
1 Blue under
Blow-by
items)
period)
the cause.
Confirm
Condition
Questions
due to length
to confirm
.g
from
(judging
liaht
load
I,
I,
are found
of interference
pickup
in oil
is heard
fl
is poor and coml
exhaust
manifold
of some
is touched
Seal on iniection
cylinders
immedjately
is low
after
starting
our-no has come
off
I 1
gas
engrne.
62
20-78
gas is excesswe
temperature
g
C
S-l 6 Vibration is excessive

* If there is abnormal noise together
vibration,
carry out troubleshooting
with
the
for Abnor-
mal noise is made.

General causes why vibration
is excessive
. Defective parts (abnormal wear, breakage)

* Improper alignment
* Abnormal combustion
Legend
0
:
:
:
::
_z
0
Possible
Most
causes
probable
Possible
causes
Vibration
Exhaust
(judging
causes
due to length
follows
Injection
engine
Questions
from
and check
Questions
of use (used
items)
and Check
for a long
items)
period)
speed
gas is black
Seal on injection
1 Remove
from
(judging
pump
0
has come
oil pan and check
directly
pump
that
test shows
off
injection
I.1
amount
is incorrect
20-79
TROUBLESHOOTING
CHART FOR ELECTRONIC
VEHICLE MONITORING SYSTEM
(M MODE)
M-l.
When
starting
switch
is turned
ON, monitor
panel display
does not appear
M-2.
When
starting
switch
is turned
ON, monitor
panel display
does not go out
M-3.
When
starting
switch
is turned
ON (engine
M-4.
Preheating
M-5.
When
operation
starting
(but there
switch
is turned
is no abnormality
M-6.
Buzzer does not sound
M-7.
There
M-8.
Monitor
M-9.
is not being
is no abnormality
panel
lighting
ON and engine
with
engine
displayed
when
does not move
. Service
meter
continues
starting
on monitor,
to move when
ON (engine
M-16.
20-83
20-85
_.
_.
.
.
.
20-86
20-91
stopped)
engine
abnormally
is stopped
M-l 1.
M-15.
20-82
. 20-91
20-92
is started
.............
Coolant temperature
gauge does not give a display
..........................
Fuel level gauge always displays FULL
...........................
Fuel gauge does not give any display
...................
Speedometer
display does not work normally
Turn signal indicator pilot lamp does not light up ................
High beam pilot lamp does not Ilight up .........................
M-14.
20-82
items flash
is turned
Coolant
M-13.
displays
up
) .
but buzzer sounds
after engine
switch
lights
caution
M-10.
M-12.
gauge
is started,
or CHECK items
does not light up
meter
display
..
.
.
.
..
. .
.
.
check items flash
used but preheating
for 1 minute
. Service
temperature
stopped),
.....
20-93
20-94
low temperature
20-95
20-96
20-96
20-97
20-98
20-99
20-81
0
M-l
WHEN STARTING SWITCH IS TURNED

DISPLAY DOES NOT APPEAR.
When
disconnecting
When
connecting
After
a)
NONE OF MONITOR
checking,
connectors
to connect
the T-adapter,
connect
connect
the disconnected
Is voltage between
chassis ground and fuse 13 20 - 30 V?
1) Turn starting
switch ON.
b)
connectors
adapter),
to the socket
always
specified
PANEL
turn the starting

in
switch
Cause
YES
1) Connect T-adapNO
ter to CN18 (female).
2) Turn starting switch ON.
Remedy
Defective monitor module
Replace
Defective contact, or disconsection in wiring harness

Jetween CN18 (female) (1)
- CN25 (4) - CN13 (3) -fuse
13, or between CN18 (female) (2) - chassis ground
After inspection, repair

(clean) or replace
3lown fuse
After finding
case, check for
short circuit in
wiring harness
Defective monitor module.
Replace
defective monitor module.
Replace
PANEL DOES NOT WORK.
Tester
T-adapter or socket adapter
(for DLl)
a) Related
electrical
CNIE
circuit
drawing
CN25
CNl3
Fuse
13
Monitor
module
Fl
2
235FO2088
M-2 WHEN STARTING SWITCH IS

TURNED ON, MONITOR PANEL
DISPLAY DOES NOT GO OUT.
20-82
OFF.
).
again immediately.
Is voltage behveen
CN18 (female) (I)
and (2) 20 - 30 V?
PART OF MONITOR
Troubleshooting
tools
M-l
(or socket
PANEL WORKS.
2
YES
, -
the T-adapter
the male and female
ON, MONITOR
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),

CHECK ITEMS FLASH.
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch
*
When
connecting
After checking,
a)
sl
the T-adapter,
connect the male and female
connect the disconnected
connectors
to the socket specified
Defective
level
3
YESI
YES
radiator
Defective
monitor
harness,
tact
2) Connect
disconnect
CN39
(female)
starting
(3)
in wiring
between
male)
CN18
NO
con-
CN39
(fe-
(3) - CN25 (7) (female)

(7).
harness,
to CN39
module
or defective
Disconnection
adapter)
coolant
Replace
Replace
CN39
(or socket
Remedy
sensor
Disconnection
2) Turn
OFF.
1.
Cause
VFS
1) Connect
again immediately.
(COOLANT LEVEL) FLASHES.
in
in wiring
or defective
con-
tact between
CN39 (female) (2) - CN25 (3) -
(female).
chassis
Table
CN39
(3) -
ground.
After
inspec-
tion,
repair
(clean)-or
re-
place
After
tion,
inspecrepair
(clean)
or re-
place
Continuity
(2)
Connect
Yes
Disconnect
No
(ENGINE OIL LEVEL) FLASHES.
YES
Defective
Does
go out?
NO
_
1) Connect
male)
level
CN35
(engine
sensor)
chassis ground.
2) Turn starting
switch
ON.
(feto
2
Is there
oil
engine
oil level
sensor
CNI 8 (fe(6) -
(Z)?
(See table)
1) Connect
NO
(female).
2) Connect
CN35
male)
monitor
Defective
connection
contact,
or disin wiring
har-
ness
T-adapter
to CN18
nect
Defective
module
Replace
continuity
between
male)
YES
Replace
and
discon-
between
CN35
(fee-
After
tion,
male)
(1) -
CN15
(1) -
(clean)
CN26
(2) -
CN18
(female)
place
inspecrepair
or re-
(6).
Table
(feCN35
chassis
chassis
ground.
Tester
ground
Continuity
Connect
Yes
Disconnect
No
Short
socket
adapter
Troubleshooting
tools
T-adapter
ifor DLl)
or socket
adapter
T-adapter
or socket
ffor Econoseal)
adapter
20-83
cl
El
b
(hydraulic
oil level) flashes.
ES
-I
1
Does @j go out
when short connector is connected?
r-l
Connect short connector to CN36 (female) (hydraulic

oil level sensor).
2) Turn starting
switch ON.
1)
M-3
a) Related
2 YES
rl0
electrical
circuit
Defective
hydraulic
oil sen-
SOT
Defective
Is continuity between CN18 (female) (5) and (2)

as shown in table?
1) Connect T-adaoter
to CN18 (femaie).
2) Connect * disconnect CN36 (female) and shortconnector.
Remedy
Cause
monitor
module
Defective contact, or disconnection in wiring harness between CN36 (female) (1) - CN25 (8) CN18 (female) (5). or between CN36 (female) (2) CN25 (3) - chassis ground
NO
Table
^,.
,.
anorr SOCKBT:
adapter
Replace
Replace

(clean) or replace
Continuity
drawing
CN18
CN25
CN39
Monitor
module
Coolant
level sensor
235FO2089
M-3
b) Related
electrical
circuit
CNl8
drawing
CN15
CN26
CN35
Monitor
module
Engine
oil level sensor
235FO2090
M-3
c) Related
electrical
CNl8
Monitor
module
circuit
drawing
CN25
CN36
Hydraulic oil
level sensor
235FO2091
20-84
M-9
Service
Service
meter does not move after engine is started

meter continues to move when engine is stopped
When
disconnecting
When
connecting
After
a)
Service
checking,
connectors
connect
meter
to connect
the T-adapter,
connect
the disconnected
the T-adapter
(or socket
the male and female

connectors
does not move after engine
adapter),
to the socket
always
turn the starting
specified
is started
Remedy
Cause
YES
Go to M5 a)
oil press-
ure CAUTION
lighted
lamp
up?
1) Turn
switch
YES
Defective
2) Start
Is voltage
starting
CN19
NO and
ON.
service
meter
Replace
between
(female)
(4) 20 -
(1)
30 V?
Disconnection
engine.
1) Connect
T-adapter
NO
in wiring
ness between
CN19
(4) and
(male)
CN25
hap
(female)
(5)
to CN19.
2) Turn starting
switch
3) Start
b)
Service
meter
to move when engine
Does service
meter
service
YES
stop
connected
when
1) Connect
chassis
2) Turn
) Remove CN13.) Turn starting
repair
(clean)
or re-
place
YES
switch
is stopped
Defective
engine
ure sensor
oil press-
meter
CN32
is
to chas-
sis ground?
stop?
inspec-
tion,
ON.
After
engine.
continues
Does
switch
OFF.
again immediately.
1
Is engine
switch
).
in
CN32
to
NO
ground.
starting
ON.
Wiring harness between engtne

oil pressure relay (3) - CN13 (51
- CN25 (5) - CN19 (female) (41
short circuiting with chassis
ground, or defective relay, or
defective contact, or disconnection in wiring harness between
engine oil pressure relay (2) CN13 (8) - CN15 (4) - CN32
Wiring
NO
harness
CN13 (female)
ON.
- CN19
circuiting
After
tion,
inspecrepair
(clean)
or re-
place
between
(5) -
CN25 (5
(female)
(4) short
with chassis
ground
Tester
Troubleshooting
tools
T-adapter
lfor DLI)
or socket
adapter
20-93
M-9
Related
electrical
circuit
drawing
Engine oil
pressure relay
Monitor
module
Service meter
(speedometer
module)
CN32
A
0
*
Engine oil
pressure sensor
235FO2101
M-IO COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY

LOW TEMPERATURE
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
*
When
After
connecting
checking,
the T-adapter,
connect
connect
the disconnected
the male and female

connectors
to the socket
specified
in
1) Connect short con-
switch ON.
orspray go
c
(male) cted to
und?
to CN17.
2) Connect CN17 (1)
to chassis ground.
3) Turn starting
switch ON.
20-94
switch
OFF.
).
again immediately.
Cause
YES
R
s1
Remedy
Defective coolant temperature sensor
Replace
Defective contact, or disconnection in wiring harness between CN34 (female) (2) - CN15 (2) CN25 (3) - chassis ground,
or between CN34 (female)
(1) - CN15 (3) - CN25 (9)
- CN17 (1)

(clean) or replace
Replace
M-II
COOLANT TEMPERATURE
When disconnecting
When
After
connecting
checking,
connectors
to connect
the T-adapter,
connect
connect
the disconnected
GAUGE DOES NOT GIVE A DISPLAY
the T-adapter
(or socket
the male and female

connectors
when CN34 is disconnected (lowest
2. YES
Does temperature
- -ty appear
CN17 is dis.,.+*rl +#/est
II
1) Disconnect CN17.
2) Turn starting
switch ON.
M-l 0, M-l 1 Related
CN 17
Monitor
module
electrical
always
specified
circuit
NO
in
switch
OFF.
1.
Cause
Remedy
Defective coolant temperature sensor
Replace
Wiring harness between

CN34 (female) (1) - CN15
(3) - CN25 (9) - CN17 (1)
short circuiting with chassis ground

(clean) or replace
IReplace
drawing
CN25
@
turn the starting
again immediately.
YES
1) Disconnect CN34.
2) Turn starting
switch ON.
adapter),
to the socket
CN15
CN34
Coolant
temperature
sensor
CNIE
235FO2094
20-95
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL

* When disconnecting connectors to connect the T-adapter (or socket adapter), always
*
When
After
connecting
checking,
the T-adapter,
connect
connect
the male and female
the disconnected
connectors
to the socket
turn the starting
specified
in
switch
OFF.
).
again immediately.
YES
Defective
Wiring
2
1) Disconnect
(fuel level
Does
CN33
sensor).
gage
out?
2) Turn starting
switch
ON.
3) Wait
min.
fuel
YES
(female)
(4) -
CN7
with
go
short
switch
between
After
CN26
CN33
inspec-
tion, repair
(clean) or re-
(1)
circuiting
place
ground
1) Disconnect
CN17.
2) Turn starting
3) Wait
min.
Replace
sensor
(3) -
(9) -
chassis
Defective
for approx.
level
harness
CN17
(female)
level
dispav
fuel
monitor
module
Replace
NO
ON.
for approx.
M-13 FUEL GAUGE DOES NOT GIVE ANY DISPLAY
ES
Does
FULL
NO
Is there
1) Disconnect
sensor
Defective
monitor
module
Defective
contact,
or dis-
Replace
sensor).
short
male)
con-
YES
CN17
chassis
connection
ground?
ness
1) Disconnect
3) Turn starting
switch
ON.
2) Connect
for approx.
CN17.
short
NO
con-
in wiring
between
male)
(3) -
(9) -
CN33
CN17
CN26
(I)
After
har-
tion,
(fe-
(4) -
(female)
CN7
date
T-adapter
(female).
Tester
Short
socket
adapter
Troubleshooting
tools
M-12,
T-adapter
(for DLI)
M-13
Related
CNI?
or socket
adapter
T-adapter
or socket
adapter
(for Econoseal)
electrical
circuit
CN26
drawing
CN33
Monitor
module
Fuel
level
sensor
235FO2102
20-96
inspecrepair
(clean)
nector.
3) Connect
to CN17
min.
Fieolace
(fe-
(3) and
nector.
4) Wait
level
continuity
between
CN33
level
2) Connect
fuel
display
appear?
(fuel
Defective
or re-
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY

* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
*
When
After
connecting
checking,
the T-adapter,
connect
connect
the disconnected
the male and female

connectors
to the socket
specified
in
switch
OFF.
).
again immediately.
Cause
YE!
Defective
Remedy
speedometer
Replace
module
setting
of speed
sensor
0.5 -
1.5
Defective
speed
sensor
Replace
mount
0
It It contacts
.,.
_
turn.
tweclt
bIYLV
male)
(7) and
300 R -
Is resistance
be-
tween
(male)
(I) and
CN30
Connect
(6)
(male)
T-adapter
to
Defective
male)
gggi$gj
CN20 (2).
and CN26
After
inspec-
tion,
repair
(clean)
or re-
olace
(61, (7)
contact,
connection
ness
sor) (male).
contact,
or disin wiring
har-
ness between
(10) (female)
NO
1 kR?
(socket adapter)
CN26 (female).
(2) 300 R -
Defective
connection
,Ic-
or dis-
in wiring
between
CN26
(6), (7) and
har(fe-
CN30
(I),
After
inspec-
tion,
repair
(clean)
or re-
place
(2)
Defective
speed
sensor
Replace
NO
Troubleshooting
tools
T-adapter
(for
M-14
Related
electrical
CN20
Monitor
or socket
adapter
T-adapter
(for
DLI)
circuit
or socket
adapter
Econoseal)
drawing
CN 26
CN30
3
Speedometer
module
sensor
235FO2103
20-97
M-15 TURN SIGNAL

t
The turn signal indicator
a)
Right turn signal
INDICATOR
PILOT LAMP DOES NOT LIGHT UP
lamp itself lights up.
indicator
pilot lamp
Remedy
1 YES
Is voltage between
CN20 (female) (3)
and chassis
ground normal?
1) Connect T-adapter NO
to CN20.
2) Turn starting
switch ON.
3) Turn right turn signal indicator
switch ON.
4) Switches between
20 -30 V and 0 V
in turn.
b)
Left turn signal indicator
Replace
Defective contact, or disconnection in wiring harness between CN20 (female) (3) and CN40 (female) (3)

(clean) or replace
Defective speedometer
module
Replace
pilot lamp
YES
Is voltage between
CN20 (female) (11)
and chassis
ground normal?
1) Connect T-adapter
to CN20.
2) Turn starting
switch ON.
3) Turn left turn signal indicator
switch ON.
4) Switches between
20 - 30 V and 0 V
in turn.
Defective speedometer
module
Defective contact, or disEonnection in wiring harness between CN20 (fenale) (11) and CN40 (female) (2)
NO
Tester
Troubleshooting
tools
M-l 5 Related
T-adapter or socket adapter

1 (for Dil,
electrical
circuit
I
I
drawing
CN40
Turn signal switch
Speedometer
module
To
turn signal
lamp (L.H.)
To
turn signal
lamp (R.H.)
235FO2104
20-98

(clean) or re-
TROUBLESHOOTING
CHART FOR ELECTRONIC
(ENGINE, PARKING BRAKE, TRANSMISSION
CONTROL)
(E MODE)
does
Starting
motor
E- 3
Parking
brake
E- 4
Parking
E- 5
Transmission
Fl and F8, or RI and R8 ..................................................................
20-108
E- 6
Transmission
does
not shift to 1st (F and R) ..................................................................
20-I 14
E- 7
Transmission
does
not shift
to 2nd (F and R) ................................................................
.20-l
14
E- 8
Transmission
does
not shift
to 3rd (F and R) .................................................................
.20-l
14
.20-l
15
brake
*
*
*
*
does
not turn
............................................................................................
20-I 02
not work .............................................................................................
20-I 06
cannot
does
between
works).
20-102
E- 2
does
motor
.................................................................
Engine
a position
not start
(starting
E- 1
be released
not shift
when
...................................................................................
transmission
lever
is moved
20-106
to
E- 9
Transmission
does
not shift to 4th (F and R) .................................................................
E-10
Transmission
does
not shift to 5th (F and R) ..................................................................
E-l 1
Transmission
does
.20-l
15
E-12
Transmission
does
.20-l
16
E-13
Transmission
does
not shift to 8th (F and RI ..................................................................
20-I 15
20-I 16
If the controller
displays
an error on machines
mounting
a transmission
controller
(Serial No.:
12013 - 12015, 12019 and up), carry out troubleshooting
for the transmission
system first.
When disconnecting
or connecting
the T-adapter
(or socket adapter)
or short socket adapter,
or
when disconnecting
the connector
for checking, turn the starting switch OFF to prevent accidents.
1)
When connecting
T-adapter
(or socket adapter),
connect to the connector
specified.
(CNxx(
When disconnecting
connectors
or connecting
T-adapters,
return them to the original
condition
immediately
after checking,
then go to the next check.
If the diagnosis
indicates
a defect in the shift controller, replace the sensor assembly (a diode and
relay are assembled on the print board, so use the input from the rotary switch to output the signal
voltage to drive the solenoid valve inside the transmission),
the F-R switch assembly
and the
rotary switch assembly,
do not disassemble
the assemblies,
otherwise
dust or other impurities
may get inside and cause secondary failures.
20-101
0
TROUBLESHOOTING
E-l
E-l
Engine does not start (starting
motor works).
Cause
2 YES
lefective
notor.
engine stop
Remedy
qeplace
Sjg-jH* Turn starting
ES
switch OFF.
- Disconnect
CN51.
NO
3 YES
1
Is voltage of
CN51 (4) 20 3OV?
. Turn starting
switch ON.
* Disconnect
CN51
- Starting switch
at both ON and
OFF.
NO
E-2 Starting
Serial
Iefective relay, or
lefective contact, or
lisconnection
in wiring
rarness.
?epair or
replace.
Iefective
notor.
?eplace
engine stop
Iefective relay, or
lefective contact, or
lisconnection
in wiring
rarness.
Repair or
replace.
Iefective contact, or
jisconnection
in wiring
rarness between battery
elay and CN51 (4).
Repair
, Disconnection of starting
motor START circuit, or
defective contact.
t Defective starting motor.
Repair or
replace.
lisconnection in wiring
jarness between ground
:onnection - CNTOl (11) otary switch - CNTOI (2) )rint board - CNT02 (2) itarter relay, CN RST 12)
nside transmission box.
Reoair
- Defective
contact, or
disconnection in wiring
harness between start in
motor (E)_ - CN14 (5).
. Defective relay or RPST.
Repair or
replace.
iisconnection in wiring
larness between parking
rwitch and tarting motor
clay.
Repair
Defective fuse (No. 14), or

fefective power circuit.
Repair
motor does not turn.
No. 11001 - 11030

3
YES
YE s
starting
switch ON.
* Turn parking
1
switch ON.
s Connect Tadapter (or
socket) to CN 14
(female) (male).
- Turn
20-l 02
0
ON.
Place shift lever at
N position.
* Turn parking
- Turn
Is voltage
between CN14
starting
switch ON.
. Turn parking
switch ON.
. Connect Tadapter (or
socket) to CN14
(female).
switch
between CN14
(5) and starting
i
NO
Turn starting
switch ON.
* Turn parking
switch ON.
-
NO
E-2
TROUBLESHOOTING
Serial
No. 11031 - 12012,
12016 - 12018
Cause
2
YES
CN14 (famale) (1)

and chassis ground
1) Turn starting
switch ON.
Serial
Disconnection
in wiring
harness between starting
motor (E) and CN14 (5)
YES
Is there continuity
between CN14 (5) _
and chassis
ground?
NO
I) Turn starting
switch ON.
2) Place shift lever at P.
3) Connect T-adapter to CN14 (male) (female)
Failure of starting motor

relay or rotary switch or
disconnection
in wiring
harness between CN14
(male) (5) -starting
motor relay- rotary
switch -chassis ground
Defective
wiring
IO
No. 12013 - 12015,
warning
starting
ON.
Repair
Remedy
Use error code display to

inspect location of
abnormality
YES
Is there continuity
lamp flash and is
switch
Replace
12019 and up
YES
1) Turn
Repair
power source
Cause
controller
Remedy
NL!Ft5&J
gg%_..
,p
3) Connect T-adapter
seconds after
starting switch
is turned ON
NO
to CN14 (male) (female
Disconnection
in wiring
harness between starting
motor(E) and CN14 (5)
Failure of starting motor
relay or disconnection
in
wiring harness between
CN14 (male) (5) -starting
motor relay -chassis
ground
Defective
wiring
power source
Repair
Replace
Repair
20-l 03
0
E-2
TROUBLESHOOTING
E-2 Related
electrical
circuit diagram
Serial No. 11001 - 11030

Cbj27
CN15
ctq55
CNST
3
Start
CN8
ine
73
0422
-3
Rotary
switch
CN14
Start
motor
ina
From
CN9
3
3
3
battery
Battery
relay
TWCOO307
20-104
0
E-5
TROUBLESHOOTING
4) Transmission
shifts to 1st to 4th (F and RI but not to 5th to 8th
Cause
Remedy
(F and R).
Serial No.:11001 - 12012,12016-
12018
2 YES
Is voltage between
YES CNT03 (4) - CNTOI
- (11) -ground
1
connection 20 3OV?
Is voltage
between CNTO3 (1 j - (4) 20 - 3OV?
No
* Turn starting
switch ON.
* Place shift lever
between 5th and 8th.
* Turn
starting
switch ON.
- Place shift
lever between
5th and 8th.
. Connect Tadapter (or
socket) to
CNT03 (male).
5)
NO
Transmission
Defective transmission
high solenoid valve.
Replace
* Defective contact, or
disconnection
in wiring
harness.
- Defective print board
circuit.
Repair or
replace.
iisconnection
in wiring
>arness between CNT03
and transmission
solenoid valve.
Repair
Iefective transmission
ow solenoid valve.
Replace
shifts to 5th to 8th (F and R) but not to 1st to
4th (F and R).
SerialNo.:11001-12012,12016-
12018
2 YES
YES
_
1
Is voltage
between CNT03
(I) and (3) 20 3OV?
I
. Turn starting
switch ON.
- Place shift
lever between
1st and 4th.
* Connect Tadapter (or
socket) to
CNT03 (male).
Is voltage
between CNT03
I3)-CNTOl (II)ground
connection 20 3OV?
NO
Defective contact, or
disconnection
in wiring
harness.
Defective print board
circuit.
iisconnection
in wiring
iarness between CNT03
Ind transmission
solenoid valve.
Repair or
replace.
Reoair
20-113
0
E-6, E-7, E-8
TROUBLESHOOTING
E-6 Transmission
does not shift to 1st (F and R).
Serial No.: 11001 - 12012,
12016 - 12018
Cause
2
YES
1 Is voltage between
CNTOZ 14) and
CNTOl 13). CNT02 (6) and CNTOI (3)
20 - 3OV?
Is voltage
between CNTO~
(3) and (11) 203OV?
YES
No
Turn Startig
switch ON.
* Place shift lever
at 1st.
E-7 Transmission
E-8 Transmission
2 YES
CNTOI (~),CNTOP
(8) and CNTOl (5)
20 - 3OV?
. Turn starting
switch ON.
- Place shift lever
at 3rd.
20-114
0
between CNTOI
(5) and (11) 20 3OV?
- Turn
stafiiw
switch ON.
* Place shift lever
3rd.
1
NO
Repair
Defective
switch.
Repair or
replace.
inside rotary
disconnection
in siring
harness of rotary switch.
Repair
* Defective p;int board

circuit.
- Defective contact, or*
disconnection
in wiring
harness between print
board and connector.
Replace
IIefective
switch.
Repair or
replace.
Reoair
12016 - 12018
Is voltage
Is voltage between
CNTOZ (4) and
Replace
* Defective print board

circuit.
- Defective contact, or
disconnection
in wiring
does not shift to 3rd (F and R).
Serial No.: 11001 - 12012,
YES
disconnection
in siring
12016 - 12018
1
NO
1 -
Repair or
reolace.
does not shift to 2nd (F and R).
Serial No.: 11001 - 12012,
. Turn starting
switch ON.
* Place shift lever
atr 2nd.
inside rotary
1
NO
* Turn starting
switch ON.
* Place shift lever
at 1st.
Defective
switch.
Remedy
inside rotary
No
zlisconnection in siring
larness of rotary switch.
. Defective print board

circuit.
disconnection
in wiring
Replace
Repair
E-S, E-10, El1
TROUBLESHOOTING
E-9 Transmission
Serial
does not shift to 4th (F and R).
No.: 11001 - 12012,
12016 - 12018
2 YES
Is voltage
YES between CNTOI
1 - (6)and (11) ZO3OV?
Is voltage
between CNTOZ
(4) and CNTOI (6), _
CNT02 19) and
CNTOl (6) 20 3OV?
. Turn starting
switch ON.
- Place shift lever
at 4th.
NO
switch ON.
Place shift levr
at 4th.
- Defective
E-lOTransmission
Serial No.: 11001 - 12012,
YES
Is voltage
between CNT02
(5) and CNTOI (7),
CNTOZ 16) and
CNT02 (7) 20 3OV?
. Turn starting
switch ON.
* Place shift lever
at 5th.
Is voltage
between CNTOI
(7) and (11) 20 3OV?
* Turn
starting
switch ON.
* Place shift lever
at 5th.
Serial
1 boardandconnector
Defective
switch.
inside rotary
NO
disconnection
in wiring
- Defective
print board
circuit.
. Defective contact, or
disconnection
in wiring
NO
E-l 1 Transmission
print board
circuit.
disconnection
in wiring
12016 - 12018
2 YES
disconnection
in wiring
NO
1 -
inside rotary
* Turn starting
Defective
switch.
No.: 11001 - 12012,
12016 - 12018
20-115
0
TROUBLESHOOTING
E-12, E-13
E-12Transmission
Serial
No.: 11001 - 12012,
12016 - 12018
Cause
,EiZ
ES
between
i-------NO
CNTOl (9), CNTOS

(8)and CNTOl (9)
swtich ON.
* Place shift lever
* Turn starting
switch ON.
* Place shift lever
at 7th.
19)and CNTOI
20-3OV?
(IO)
* Turn starting
switch ON.
- Place shift lever
at 8th.
20-l16
0
Is voltage
between CNTOI
(IO) and (11) 203OV?
' Turn
starting
switch ON.
* Place shift lever
at 8th.
1
NO
Repair or
replace.
or
disconnection
in wiring
Replace
Repair
12016 - 12018
Is voltage between
CNTOZ(5) and
CNTOl(lO), CNTOP
print board
-Defectivecontact,
No.: 11001 - 12012,
mz
1
inside rotary
disconnection
in wiring
*Defective
circuit.
E-13Transmission
Serial
Defective
switch.
CNTOl
YES
Iefective
switch.
inside rotary
Repair or
replace.
No
disconnection
in wiring
larnss of rotary switch.
Repair
* Defective print board

circuit.
disconnection
in wiring
Replace
Repair
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(ET MODE)
023502
LED display for transmission controller .............................................................................................. 20-152

ET- 1
[A1] (Short circuit in 1st solenoid) is displayed .................................................................. 20-156
ET- 2
[A2] (Short circuit in 2nd solenoid) is displayed ................................................................. 20-157
ET- 3
[A3] (Short circuit in 3rd solenoid) is displayed .................................................................. 20-158
ET- 4
[A4] (Short circuit in 4th solenoid) is displayed .................................................................. 20-159
ET- 5
[A5] (Short circuit in High/Low solenoid) is displayed ....................................................... 20-160
ET- 6
[A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed ....................................20-162
ET- 7
[b1] (Disconnection in 1st solenoid) is displayed ............................................................... 20-164
ET- 8
[b2] (Disconnection in 2nd solenoid) is displayed .............................................................. 20-165
ET- 9
[b3] (Disconnection in 3rd solenoid) is displayed .............................................................. 20-166
ET-10
[b4] (Disconnection in 4th solenoid) is displayed ............................................................... 20-167
ET-11
[b5] (Disconnection in Low solenoid) is displayed ............................................................. 20-168
ET-12
[b6] (Disconnection in High solenoid) is displayed ............................................................ 20-169
ET-13
[b7] (Disconnection in FORWARD solenoid) is displayed .................................................. 20-170
ET-14
[b8] (Disconnection in REVERSE solenoid) is displayed .................................................... 20-171
ET-15
[c1] (Disconnection in inching potentiometer) is displayed .............................................. 20-172
ET-16
[c2] (Failure in shift potentiometer 1) is displayed ............................................................ 20-173
ET-17
[c3] (Failure in shift potentiometer 2) is displayed ............................................................ 20-174
ET-18
[d1] (Failure in F and R switches) is displayed ................................................................... 20-175
ET-19
[d4] (Disconnection in engine speed sensor) is displayed ................................................ 20-176
ET-20
[d5] (Disconnection in speed sensor) is displayed ............................................................. 20-177
ET-21
[d6] (Failure in transmission oil temperature sensor) is displayed .................................. 20-178
ET-22
[E0] (Drop in power source voltage) is displayed .............................................................. 20-179
ET-23
[E1] (Short circuit in parking brake) is displayed ................................................................ 20-181
ET-24
[E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed .............. 20-182
ET-25
[E3] or [F3] (Short circuit, disconnection in differential lock relay) is displayed ........... 20-183
ET-26
[E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed ............. 20-185
ET-27
[E5] or [F5] (Short circuit, disconnection in caution lamp) is displayed ......................... 20-187
ET-28
[E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed ................ 20-188
ET-29
[E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed ............. 20-190
ET-30
[F1] (Disconnection in parking brake) is displayed............................................................. 20-192
ET-31
[C4] (Disconnection in rotary switch photo-interrupter) is displayed .............................. 20-194
ET-32
[C5] (Abnormality in rotary switch photo-interrupter) is displayed .................................. 20-195
20-151
(8)
TROUBLESHOOTING
LED DISPLAY FOR TRANSMISSION CONTROLLER

Serial No. 12013 12015, 12019 12098
1) Self-diagnostic display
The error code is displayed by LEDs using a 2-digit code. If an abnormality is detected, the warning
lamp and alarm buzzer are actuated.
2) Method of displaying error codes and abnormal operation codes again
Turn the starting switch OFF ON and the error code and abnormal operation code will be
displayed in the following order:
[CHECK.SUM] [Past failures] [Existing failures] [Abnormal operation]
When the [Abnormal operation] display finishes, the [Existing failure] display is repeated.
Abnormal system and content of abnormality
Troubleshooting
code
Warning
lamp
Alarm
buzzer
ET-1
ET-15
ET-16
ET-17
(ET-1617)
(ET-1617)
ET-19
ET-20
A1
Short circuit in 1st clutch solenoid output system
A2
Short circuit in 2nd clutch solenoid output system
A3
Short circuit in 3rd clutch solenoid output system
A4
Short circuit in 4th clutch solenoid output system
A5
Short circuit in High/Low clutch solenoid output system
A7
Short circuit in FORWARD/REVERSE clutch solenoid output system
b1
Disconnection in 1st clutch solenoid output system
b2
Disconnection in 2nd clutch solenoid output system
b3
Disconnection in 3rd clutch solenoid output system
b4
Disconnection in 4th clutch solenoid output system
b5
Disconnection in Low clutch solenoid output system
b6
Disconnection in High clutch solenoid output system
b7
Disconnection in FORWARD clutch solenoid output system
b8
Disconnection in REVERSE clutch solenoid output system
c1
Disconnection in inching potentiometer system
c2
Abnormality in voltage of shift potentiometer (1) signal
c3
Abnormality in voltage of shift potentiometer (2) signal
c4
Discrepancy in shift potentiometers (1), (2) signals
c5
Abnormality in both shift potentiometer signal systems
d1
Both F and R switches are ON
d4
Disconnection in engine speed sensor system
d5
Disconnection in speed sensor system
d6
Failure in transmission oil temperature sensor
ET-21
d7
Shift lever is not at P position when starting switch is ON
20-152
(8)
ET-2
ET-3
ET-4
ET-5
ET-6
ET-7
ET-8
ET-9
ET-10
ET-11
ET-12
ET-13
ET-14
ET-18
023502
Error
code
TROUBLESHOOTING
LED DISPLAY
Abnormal
system
and content
FOR TRANSMISSION
CONTROLLER
of abnormality
z
2
16
Engine
17
Acceleration
18
Transmission
lubricating
continued
for more than
19
With transmission at neutral, travel speed above 4 km/h and

engine speed above 1400 rpm continued for more than 10 seconds
IA
With transmission
in F or R and inching pedal depressed,
travel speed above 4 km/h and engine speed above
1400 rpm continued for more than 10 seconds
Error
code
speed
Gearshifting
above
2350 rpm
to dangerous speed with inching pedal depressed
pattern
oil temperature
30 seconds
when
there
above
is abnormal
120C
operation
i F
Shifts
N +
F when
travel
speed
is above
i A
F i A
Shifts
N +
R when
travel
speed
is above
9 km/h
Shifts
F +
R when
travel
speed
is above
9 km/h
A i F
Shifts
R +
F when
travel
speed
is above
9 km/h
F i -
Shifts to F4 or above
when
travel
speed is below
2 km/h
A : -
Shifts to R4 or above
when
travel
speed
2 km/h
F i 0
Inching
used for long time
in F (FORWARD)
A i 0
Inching
used for long time
in R (REVERSE)
9 km/h
is below
I-----0
1
2
3
4
: Clutch
Clutch
Clutch
Clutch
Clutch
:
:
:
:
temperature
temperature
temperature
temperature
temoerature
below 200C
200 - 230C
230 - 260C
260 - 290C
above 290C
20-153
0
TROUBLESHOOTING
Error
code
Abnormal system and content of abnormality
E0
E1
E2
E3
E4
E5
E6
E7
F1
F2
F3
F4
F5
F6
F7
10
Power source voltage below 18 V

Short circuit in parking brake solenoid system
Short circuit in parking lamp system
Short circuit in differential lock solenoid system
Short circuit in backup buzzer system
Short circuit in caution lamp system
Short circuit in alarm buzzer system
Short circuit in starting motor relay system
Disconnection in parking brake solenoid system, short circuit
Disconnection in parking lamp system, short circuit
Disconnection in differential lock relay system, short circuit
Disconnection in backup buzzer system, short circuit
Disconnection in caution lamp system, short circuit
Disconnection in alarm buzzer system, short circuit
Disconnection in starting motor relay system, short circuit
Detection of overrun by deceleration
Operation to switch between FORWARD and REVERSE
at above 9 km/h
Operation to shift to 4th or above at below 2 km/h
Clutch plate temperature above 200C
Inching used continuously for more than 10 seconds
Inching used continuously for more than 30 seconds
Engine speed above 2350 rpm
Acceleration to dangerous speed with inching pedal depressed
Transmission lubricating oil temperature above 120C
continued for more than 30 seconds
With transmission at neutral, travel speed above 4 km/h and
engine speed above 1400 rpm continued for more than 10 seconds
With transmission in F or R and inching pedal depressed,
travel speed above 4 km/h and engine speed above
1400 rpm continued for more than 10 seconds
11
023502
12
13
14
15
16
17
18
19
1A
Shifts N F when travel speed is above 9 km/h

Shifts N R when travel speed is above 9 km/h
Shifts F R when travel speed is above 9 km/h
Shifts R F when travel speed is above 9 km/h
Shifts to F4 or above when travel speed is below 2 km/h
Shifts to R4 or above when travel speed is below 2 km/h
F
A
Inching used for long time in F (FORWARD)

Inching used for long time in R (REVERSE)
............. ......................................
Error
code
F
A
F A
A F
F
A
0
0
Warning
lamp
Alarm
buzzer
Troubleshooting
code
ET-22
ET-23
ET-24
ET-25
ET-26
ET-27
ET-28
ET-29
ET-30
ET-24
ET-25
ET-26
ET-27
ET-28
ET-29
Gearshifting pattern when there is abnormal operation
0
1
2
3
4
:
:
:
:
:
Clutch
Clutch
Clutch
Clutch
Clutch
temperature
temperature
temperature
temperature
temperature
below 200C
200 230C
230 260C
260 290C
above 290C
20-153-2
(8)
LED DISPLAY
TROUBLESHOOTING
3)
Saving error codes, abnormal

operation
The transmission
controller
saves any
ated, and keeps these in memory
even
As a result, when the starting switch is
ON, it is possible to check the content
Display
item
(order
Transmission
controller
power
2)
All segments
of LED light
3)
(No comment)
4)
CHECK.SUM
5)
Trouble
6)
Error codes
d4: Abnormality
Z
L
=I
Z
2
Starting
ON
up
.-P
Z
X
LLI
0
E
B
x
0
Z
E
Z
5
m
.-?
2
ul
Z
5
Z
2
?
E
2
i2
switch
OFF +
I-!
-.-. I-!
ON
.Y
0.5
.Y
0.5
display
data
in engine
speed
sensor
$
7)
If there are any other failures

Steps 5) and 6) are repeated.
8)
Existing failures
* If there are no existing
failures,
displayed
for 3 seconds.
9)
Display time
(se4
LED display
Z
5
Z
2
Y-J
I?
CONTROLLER
codes
error codes and abnormal
operation
codes that are generafter the starting
switch is turned OFF.
turned ON and the transmission
controller
power is turned
of all the abnormalities
that have occurred
so far.
of display)
1)
FOR TRANSMISSION
t3.E
is
Error codes
F4: Disconnection
in backup buzzer
system, short circuit in power source
IO) If there are any other

9) are repeated.
failures,
11) Abnormal
record
operations
12) Abnormal
operation
codes
14: Inching used continuously
10 seconds
Steps
f-u
0.5
1-i
8) and
for more
13) Gearshift
pattern code when there is
abnormal
operation
FO: FORWARD, clutch temperature
below
14) Number
of times of operation
abnormal
operation
02: 2 times
c(
in memory,
than
0.5
P+
FE
r:-- ,I
200C
of this
15) If there are any other abnormal

operations
in memory,
Steps 11) to 14) are repeated.
When the display

of abnormal
operations
in
memory is completed,
display returns again to
existing failures.
* If there are no existing failures, fi.3
is
displayed.
20-154
0
TROUBLESHOOTING
Method of deleting error codes from memory

After carrying out troubleshooting and completing repairs of the failure, the self-diagnostic display
returns to the normal display. Always do as follows to delete the transmission controller error
codes from memory.
The abnormal operation items are deleted from memory at the same time.
023502
(1) Turn the starting switch to the ON position, and after completing the display for all the past
.
failures in memory, check that the display returns to
(2) Take the connector (color of wiring harness: green) connected to connector number [FR] inside the
right console box, and ground it to the chassis. (When doing this, make sure that the starting
switch is at the ON position.)
After grounding the connector, install the blind connector to the FR connector in the original
way.
(3) Turn the starting switch OFF, then turn it ON again and check that the past error codes have been
deleted from memory.
If the past error codes have been deleted from memory, CHECK.SUM is displayed, then
is displayed immediately.
20-155
(8)
ET-1
TROUBLESHOOTING
ET-1
*
*
*
[Al]
(Short circuit in 1st solenoid)
is displayed
This troubleshooting
is carried out when there is still an abnormality,
so when disconnecting
the
connector
and inserting
the T-adapter,
or when removing
the T-adapter
and returning
the connector to its original
position,
if the error code for [Existing failure]
is no longer displayed
on the LED
display, the problem
has been removed.
Before carrying
check that all the related connectors
are properly
inserted.
Always connect any disconnected
connectors
before going on to the next step.
Cause
1Is voltage
YES
GotoA
H
11[ZFn
y$ijiij!;;;g.
When
II
(female) (2) and

chassis normal?
1st is
YES
betwee,st
Is resistance
(male) (1) and (2)
normal?
-5-20R
-Turn starting
switch OFF.
* Disconnect 1st.
NO
switch OFF.
* Disconnect 1st
and E2.
NO
4 YES
Aj$!jnLJHP
electrical
Short circuit with power

source in wiring harness
between 1st (female) (2)
and E2 (female) (17)
Repair or
replace
Short circuit in wiring

harness between E2 (7)
and 1st (I) and wiring
harness between E2 (17)
and 1st (2)
Repair or
replace
Defective
1st solenoid
Replace
Defective
controller
transmission
Repair or
replace

and E2 (female) (7)
* Max. 0.1 V
NO
* Turn starting
switch OFF.
* Disconnect 1st and E2.
* Turn starting switch ON.
ET-1 Related
Remedy
Repair or
circuit diagram
Transmission
controller
1st
solenoid
(+I
1st
solenoid
(-1
E2
1st
1st
solenoid
TWG00317
20-156
0
ET-2
TROUBLESHOOTING
ET-2
Ir
*
t
[A21 (Short circuit in 2nd solenoid)
is displayed
the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED
display, the problem has been removed.
Before carrying out troubleshooting,
check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES
GotoA
Is voltage
YES
2
is
disconnected, is
resistance between
E2 (female) (81 and
(18) normal?
* Min. 1 MR
*Turn startina
switch OFF.. Disconnect 2nd
and E2.
between 2nd
(female) (2) and
chassis normal?
When 2nd
YE
1
(male) (1) and (2)

-5-20Q
-Turn starting
switch OFF.
- Disconnect 2nd.
* Max. 0.1 V
NO
-Turn starting switch OFF.
* Disconnect 2nd and E2.
- Turn starting switch ON.
hln
*
4 YES
AjZHP
I
NO
Max. 0.1 V
*Turn starting
switch OFF.
*Turn starting switch ON.
electrical
Transmission
Repair or
replace

harness between E2
(female) (8) and 2nd
(female) (1) and wiring
harness between E2
(female) (18) and 2nd
(female) (2)
Repair or
replace
Defective
2nd solenoid
Replace
Defective
controller
transmission
Repair or
replace

between 2nd (female) (1)
and E2 (female) (8)
ET-2 Related

Repair or
replace
circuit diagram
controller
E2
2nd
2nd
solenoid
20-157
0
ET-3
TROUBLESHOOTING
the
Cause
3
Is voltage
between 3rd
(female) (2) and
chassis normal?
YES
2 YE
1
(male) (1) and (2)

*5-20R
. Turn starting
switch OFF.
s Disconnect 3rd.
When 3rd is
disconnected,
is
- resistance between
E2 (female)
(9) and
119) normal?
* Max.
* Min. 1 MC2
* Turn starting
switch OFF.
* Disconnect 3rd
and E2.
0.1 V
YES
GotoA
NO
Turn starting switch OFF.

* Disconnect 3rd and E2.
NO
,h
IV
4 YES
+ZJgJH--
* Max.
0.1 V
NO
Turn starting
switch OFF.
electrical
Transmission

between 3rd (female) (2)
Repair or
replace

harness between E2
(female) (9) and 3rd
harness between E2
(female) (19) and 3rd
(female) (2)
Repair or
replace
Defective
3rd solenoid
Replace
Defective
controller
transmission
Repair or
replace

and E2 (female) (9)
ET-3 Related
Remedy
Repair or
replace
circuit diagram
controller
I
E2
3rd
3rd
solenoid
(+I
3rd
solenoid
(-1
3rd
solenoid
TWG00319
20-l 58
0
ET-4
TROUBLESHOOTING
ET-4
+
*
*
[A41 (Short circuit in 4th solenoid)
is displayed
the
Remedy
Cause
3
YES
2 -
YES
GotoA
Is voltage
between 4th
(female) (2) and
chassis normal?
I When 4th is
YES disconnected, is
* Max. 0.1 V
- resistance between *Turn starting switch
E2 (female) (101and
1
* Disconnect 4th and
p
(201normal?
_
Is resistance
*Turn starting switch
* Min. 1 MCI
between 4th
- *Turn starting
NO
(male) (1) and (2)
switch OFF.
normal?
* Disconnect 4th
-5-20R
and E2.
* Turn starting
NO
switch OFF.
* Disconnect 4th.
NO
OFF.
E2.
ON.
4 YES
+GjjiJH-*
electrical
Transmission
Repair or
replace

harness between E2
(female) (IO) and 4th
(female) (I) and wiring
harness between E2
(female) (20) and 4th
(female) (2)
Repair or
replace
Defective
4th solenoid
Replace
Defective
controller
transmission
Repair or
replace

between 4th (female) (1)
Max. 0.1 V
NO
* Turn starting
switch OFF.
- Disconnect 4th and E2.
- Turn starting switch ON.
ET-4 Related

Repair or
replace
circuit diagram
controller
4th
E2
4th
solenoid
3
4th
solenoid
(-1
TWC00320
20- 159
0
TROUBLESHOOTING
ET-5
ET-5
[A51 (Short circuit in High/Low
solenoid)
is displayed
so when disconnecting the
Cause
Remedy
GotoA
When
YES
-
1
~
Is resistance
between Lo (male)
(1) and (2)
normal?
*5-20R
*Turn starting
switch OFF.
* Disconnect Lo.
Lo
is
disconnected.
is
resistance between
E2 (female1 (2) and
* Max.
NO
0.1 V
Turn starting switch OFF.

* Disconnect Lo and E2.
.
normal?
* Min. 1 MR
*Turn starting
switch OFF.
* Disconnect Lo
and E2.
(13)
NO
6
When
YES
5
-
~
Is voltage
between Lo
(female) (1) and
chassis normal?
disconnected,
*5-20R
-Turn starting
switch OFF.
* Disconnect Hi.
YES
Hi is
is
resistance between
E2 (female) 121and
(14) normal?
*Min. 1 MR
NO
OFF.
* Disconnect Hi and E2.
NO
.
* Max. 0.1 V
* Turn starting
NO
switch OFF.
-Turn starting switch ON.
YES
(female) (2) and

chassis normal?
B
between Hi
(female) (2) and
chassis normal?
* Max. 0.1 V
* Turn starting
switch OFF.
* Disconnect Hi
and E2.
. Turn starting
switch ON.
20-160
0

harness between E2
(female) (2) and Lo
harness between E2
(female) (13) and Lo
(female) (2)
Defective
NO
Is resistance
YES between Hi (male)
(1) and (2)
4
normal?

between Lo (female) (2)
* Max. 0.1 V
NO
-Turn starting switch OFF.
- Disconnect Hi and E2.
NO
Low solenoid
Repair or
replace
Repair or
replace
Replace
GotoB
harness between E2
(female) (2) and Lo
harness between E2
(female) (13) and Lo
(female) (2)
Repair or
replace
Defective
Replace
Hi solenoid

and E2 (female) (2)
Repair or
replace
Defective
controller
Repair or
replace
transmission

between Hi (female) (1)
and E2 (female) (3)
Repair or
replace

Repair or
replace
ET-5
TROUBLESHOOTING
ET-5 Related
electrical
circuit diagram
Lo solenoid
ransmission
controller
Lo solenoid
(+I
Hi
solenoid
(+I
Lo solenoid
(+I
id
TWG00321
20-161
0
ET-6
TROUBLESHOOTING
ET-6
-+
*
*
[A71 (Short circuit in FORWARD/REVERSE
solenoid)
is displayed
Cause
3 YES
YESI
1When
FW is
I
(female) (2) and
chassis normal?
2
s-l
l-l
* Turn starting switch OFF.

. Disconnect FW and E2.
NO
-5-20R
-Turn starting
switch OFF.
- Disconnect FW.
and E2.
YES
jZ+Z&CJH--
YES
Is voltage
between FW
(female) (1) and
chassis normal?
Is resistance
between RE
(male) (1) and (2)
normal?
* Min. 1 MD
NO
OFF.
* Disconnect RE and E2.
*5-20R
-
NO
* Turn starbng
switch OFF.
* Disconnect RE.
- Max. 0.1 V
1
* Turn starting
NO
switch OFF.
* Disconnect FW and E2.
-Turn starting switch ON.
a
YE
7
f Max. 0.1 V
-Turn starting
switch OFF.
* Disconnect RE
and E2.
* Turn starting
switch ON.
20- 162
0
Is voltage
between RE
(female) (2) and
chassis normal?
L-t
GotoA
2etween FW (female) (2)
snd E2 (female) (15)
harness between E2
(female) (2) and FW
harness between E2
(female) (15) and FW
(female) (2)
defective
solenoid
NO
YES
Max. 0.1 V
NO
* Turn starting switch OFF.
- Disconnect RE and E2.
Remedy
FORWARD
Iepair or
eplace
Iepair or
eplace
3eplace
GotoB
narness between E2
:female) (5) and RE
:female) (1) and wiring
narness between E2
ifemale) (16) and RE
:female) (2)
3efective
solenoid
3epair or
eplace
REVERSE

between FW (female) (1)
and E2 (female) (4)
Repair or
replace
Defective
controller
Repair or
replace
transmission

between RE (female) (I)
and E2 (female) (5)
Repair or
replace

between RE (female) (2)
Repair or
replace
ET-6
TROUBLESHOOTING
ET-6 Related
electrical
circuit diagram
FORWARD
solenoid
Transmlsslon
controller
FORWARD
solenoldlt)
REVERSE
solenoid(t)
FORWARD
solenold(-1
REVERSE
solenoid
TWG00322
20-163
0
ET-7
TROUBLESHOOTING
ET-7
*
*
[bll
(Disconnection
in 1st solenoid)
is displayed

check that all the related connectors are properly
Always connect any disconnected
connectors before going on to the next step.
inserted.
*
4YES1
YES
3
When
When 1st(female) (1)

YI ; Is groundedto chassis,
- ISresistancebetween -
(male) (I) and (2)

*5-20R
* Turn starting
switch OFF.
* Disconnect 1st.
ET-7 Related
1st (female)
(2)
YES isgroundedto chassis,

- is resistance between
E2 (female)(17)and
2
E2 (female1
Is resistance
E2 (female) (17).1st
ifemale) 12)and
chassis normal?
~
* Min. 1 MR
* Turn starting
switch
chassis n~~m.g
* Max. 1 R
- Turn starting
(71 and
switch
between
OFF.
. Disconnect
NO
OFF.
chassisnormal?
- Disconnect 1st and E2.
- Max. 1 R
* Ground 1st (female) (2) to chassis.
-Turn starting
NO
switch OFF.
+ Disconnect 1st and E2.
* Ground 1st (female) (1)
to chassis.
NO
Transmission
transmission
Short circuit with ground

in wiring harness
Defective contact or
disconnection
in wiring
1st and E2. 1 harness between 1st
(female) (1) and E2
(female) (17)
disconnection
in wiring
harness between 1st
(female) (I) and E2
(female) (7)
Defective 1st solenoid
(internal disconnection)
\I0
electrical
Defective
controller
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Reolace
circuit diagram
controller
1
1st
E2
1st
solenoid
C-t)
1st
solenoid
(-1
-3
1st
solenoid
TWG00317
20- 164
0
ET-8
TROUBLESHOOTING
ET-8
Ir
Sr
[b2] (Disconnection
in 2nd solenoid)
is displayed

I
4YEA
resistance between
E2 (female) 118). 2nd
(female) (2) and
chassis normal?
Is
YI
1
-5-20R
* Turn starting
switch OFF.
- Disconnect 2nd.
ET-8 Related
YES
3
When 2nd (female)
12)
YES is grounded tO chassis,
~* Min. 1 MR
NO
- is resistance between
*Turn starting
E2 (female1 (18) and
2
switch OFF.
p
chassis normal?
When 2nd (female) (1)
f Max. 1 - R
is grounded to chassis,
. is resistance between - . Turn starting
NO
E2(female) (8) and
switch OFF.
chassisnormal?
- Disconnect 2nd and E2.
* Max. 1 R
- Ground 2nd (female) (2) to chassis.
- Turn starting
NO
switch OFF.
* Ground 2nd (female) (1)
to chassis.
IO
electrical
Transmission
inserted.
Remedy
Cause
Defective
controller
transmission

in wiring harness
disconnection
in wiring
harness between 2nd
(female) (2) and E2
(female) (18)
disconnection
in wiring
harness between 2nd
(female) (I) and E2
(female) (8)
Defective 2nd solenoid
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Replace
circuit diagram
controller
I
2nd
E2
2nd
solenoid
g)
3
TWG00318
20- 165
0
ET-9
TROUBLESHOOTING
ET-9
*
Ir
Before
Always
[b31 (Disconnection
carrying
connect
any disconnected
in 3rd solenoid)
is displayed

are properly
connectors
Cause
4YEI
(female)
startina
(male) (I) and (2)

*5-20n
. Turn starting
switch OFF.
* Disconnect 3rd.
ET-9 Related
3rd (female)
Repair or
replace
Repair or
replace
Repair or
replace
Defective 3rd solenoid

JO
Transmission
Repair or
replace
disconnection
in wiring
harness between 3rd
(female) (1) and E2
(female) (9)
(2) to chassis.
NO
switch OFF.
* Ground 3rd (female) (1)
to chassis.
electrical
transmission
disconnection
in wiring
harness between 3rd
(female) (2) and E2
(female) (19)
YE
* Ground
Remedy

in wiring harness
(2) and
chassis normal?
*Turn
Defective
controller
inserted.
Replace
circuit diagram
controller
E2
3rd
3rd
solenoid
(+)
3rd
solenoid
(-)
3rd
solenoid
TWG00319
20-166
0
ET-10
TROUBLESHOOTING
ET-10
+
+
[b41 (Disconnection
in 4th solenoid)
is displayed

Remedy
Cause
Defective
controller
1 When
4th (female)
(2)
is resistance between
E2 (female) (20) and
Is
1
1chassis
- Min.
-Turn
1 /_
normal?
1 MR
starting
NI
resistance
between 4th
(male) (I) and (2)
normal?
5-20R
* Turn starting
switch OFF.
* Disconnect 4th.
ET-10 Related
chassis normal?
* Disconnect
4th and E2.
* Max. 1 R
* Ground 4th (female) (2) to chassis.
* Turn starting
NO
switch OFF.
* Disconnect 4th and E2.
. Ground 4th (female) (1)
to chassis.
Transmission
Repair or
replace

in wiring harness
Repair or
replace
Repair or
replace
disconnection
in wiring
harness between 4th
(female) (I) and E2
(female) (IO)
Repair or
replace
Defective 4th solenoid

electrical
transmission
disconnection
in wiring
harness between 4th
(female) (2) and E2
(female) (20)
YE
inserted.
Replace
circuit diagram
controller
E2
4th
4th
solenoid
TWG00320
20-167
0
ET-l 1
TROUBLESHOOTING
ET-11
Ir
*
[b51 (Disconnection
in Low solenoid)
is displayed

check that ail the related connectors are properly
inserted.
Cause
4YES
Is resistance between
E2 (female) (131, Lo
Ifemale) (2) and
YES
3 -
When Lo (female)
YES
grounded to chassis, is
resistance between E2 (female)113) and
YE
1
between Lo (male)
-5-20R
* Turn starting
switch OFF.
- Disconnect Lo.
ET-11 Related
(21 is
chassis
normal?
1
*
Min. 1 MR
NO
* Turn starting
switch OFF.
chassisnormal?
~
When Lo (femaleI (1)
* Max. 1 R
is groundedto chassis,
is resistance between * Turn starting
NO
E2 (female)(2) and
switch OFF.
chassisnormal?
.
* Max. 1 R
* Ground Lo (female) (2) to chassis.
* Turn starting
NO
switch OFF.
* Ground Lo (female) (1)
Defective
controller
transmission
Repair or
replace
disconnection
in wiring
harness between Lo
(female) (2) and E2
(female) (13)
Repair or
replace
Defective Low solenoid

electrical
Repair or
replace

in wiring harness
disconnection
in wiring
harness between Lo
(female) (I) and E2
(female) (2)
NO
Remedy
Repair or
replace
Replace
circuit diagram
Transmission
controller
Lo
E2
Lo
solenoid
(+I
Lo
solenoid
(-1
Lo
solenoid
TWG00323
20-168
0
TROUBLESHOOTING
ET-12
+
*
ET-12
[b6] (Disconnection
in High solenoid)
is displayed

1When
YES
Hi ifemalel12)
grounded
is 1
to chassis, is
resistancebetweenE2 (femalei 114) and
- Min.
1 MR
NO
* Turn starting
switch OFF.
~
chassisnormal?
When Hi (female)(1)
+ Max. 1 R
YES is groundedto chassis,
- is resistance between - * Turn starting
NO
E2 (female)13)and
switch OFF.
1
~
chassis
normal?
~
Is resistance
* Max. 1 Cl
* Ground Hi (female) (2) to chassis.
between Hi (male) _ * Turn starting
NO
(1) and (2)
switch OFF.
normal?
* Ground Hi (female) (I) to
.5-20R
1 chassis.
* Turn starting
switch OFF.
* Disconnect Hi.
ET-12 Related
electrical
Transmission
transmission

in wiring harness
disconnection
in wiring
harness between Hi
(female) (2) and E2
(female) (14)
disconnection
in wiring
harness between Hi
(female) (1) and E2
(female) (3)
Defective High solenoid
NO
Remedy
Cause
Defective
controller
(female) (2) and
chassis normal
inserted.
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Replace
circuit diagram
controller
I
Hi
solenoid
(+I
Hi
solenoid
(-1
E2
Hi
Hi
solenoid
TWG00324
20-169
0
TROUBLESHOOTING
ET-13
*
*
Before
Always
ET-13
[b7] (Disconnection
carrying
connect
any disconnected
in FORWARD
solenoid)
is displayed

are properly
connectors
Cause
4YES
YES
3 -
Is resistance between
E2 (female) (15). FW
(female) (21and
When FW(femiii
chassis normai?
YES isgroundedtochassis.
L
* Min. 1 MS2
NO
- is resistancebetween *
Turn
starting
E2(female)115)and
2
switch OFF.
~
chassisnormal?
When Hi (female)(1)
- Max. 1 R
YES Is grqundedto chassis,
- ISreelstancebetween - * Turn starting
NO
E2(female)(4) and
switch OFF.
1
~
~chassisnormal?
Is resistance
* Max. 1 f2
* Ground FW (female) (2) to chassis.
between FW
* Turn starting
(male) (1) and (2) NO
switch OFF.
normal?
* Ground FW (female) (I)
-5-200
to chassis.
*Turn starting
switch OFF.
NO
- Disconnect FW.
ET-13 Related
electrical
Transmission
Defective
controller
transmission

in wiring harness
between FW (female) (2)
disconnection
in wiring
harness between FW
(female) (2) and E2
(female) (15)
disconnection
in wiring
harness between FW
(female) (1) and E2
(female) (4)
Defective FORWARD
solenoid (internal
disconnection)
inserted.
Remedy
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
reolace
Replace
circuit diagram
controller
FW
YE2
FORWARD
solenoid
FORWARD solenoid(-)
20- 170
0
TWG00325
ET-14
TROUBLESHOOTING
ET-14
*
-)r
Before
Always
[b8] (Disconnection
carrying
connect
in REVERSE solenoid)
any disconnected
is displayed

are properly
connectors
Cause
4YES
.1
Is resistance
YES
3
YES
JZ
grounded to chassis, is
between
E2 (female) (16), RE
(female1 12) and
chassis normal?
* Min.
1 MR
Defective
controller
transmission

in wiring harness
between RE (female) (2)
disconnection
in wiring
harness between RE
(female) (2) and E2
1 (female) (16)
normal?
Ground
RE (female)
* Disconnect RE and E2.

. Ground RE (female) (1)
1 to chassis.
*5-20R
* Turn starting
switch OFF.
* Disconnect RE.
electrical
circuit diagram
Transmission
controller
E2
it
disconnection
in wiring
harness between RE
(female) (1) and E2
(female) (5)
Defective REVERSE
solenoid (internal
disconnection)
NO
ET-14 Related
(2) to chassis.
REVERSE
solenoid(t)
REVERSE
solenold(-)
16
inserted.
Remedy
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Replace
REVERSE
solenoid
TWG00326
20-171
0
TROUBLESHOOTING
ET-15
+
*
*
*
ET-15
[cl] (Disconnection
in inching potentiometer)
is displayed
Check that the inching potentiometer
mount is normal.
Remedy
Cause
3 YES
[When TM11 (female) 12) 1 7
GotoA
harness between TM11
(female) (2) and E3
(female) (4)
YES
1

in wiring harness
between TM1 1 (female)
(3) and E3 (female) (7)
f Ground TM1 1 (female) (2) to chassis.
is grounded f~ chassis,
is resistance between
E3 Ifemale) (7) and
- Max. 1 Q
-Turn starting
switch OFF.
* Disconnect TM1 1
and E3.
* Ground TM11
(female) (3) to
chassis.
* Disconnect
Disconnection in wiring
harness between TM1 1
(female) (3) and E3
(female) (7)
NO
6 YES
YES
5
Is voltage
between TM I I
(3) and (2)
normal?
* Min. 1 MR
* Turn starting
switch OFF.
* Disconnect TM1 1
and E3.
electrical
Transmission
Repair or
replace
TM1 1
When E3 is
YEIS disconnetied, is
* 0.45 - 0.61 v
NO
resistance between + Insert T-adapter into TM1 1.
TM11 (female) (1)
and (21 normal?
* Do not depress inching pedal.
* Min. 1 Ma
* Turn starting
NO
switch OFF.
* Disconnect TM1 1
and E3.
L
ET-15 Related
Repair or
replace
Repair or
replace
controller
Repair or
replace
Defective inching
potentiometer (internal
disconnection)
Replace
Defective contact in
wiring harness between
TM1 1 (female) (2) and E3
harness between TM11
(1) and E3 (16)
Repair or
replace

in wiring harness
between TM1 1 (female)
(2) and E3 (female) (4)
Repair or
replace
circuit diagram
controller
Inching
PO
E3
i ome
en
er
Inching
input
Power
SUPP
I Y (+5V)
GND
I
I
TWG00327
ZO-172
0
TROUBLESHOOTING
ET-31
ET-31 [C4] (Disconnection in totary switch photo-interrupter) is displayed

(Serial No.: 12099 and up)
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
3 YES
YES Is voltage between
T01 (female) (11)
2
and (12) normal?
When T01 (female)

(11) is grounded to
YES chassis, is resist1

When T01 (female)
(12) is grounded to
chassis, is resistance between E1
(female) (13) and
chassis normal?
ance between E1
(female) (12) and
chassis normal?
24V
NO
Connect T-adapter to
T01.
Shift lever (P).
Turn starting switch ON.
Max. 1
Turn starting
NO
switch OFF.
Disconnect T01, E1.
T01 (female) (11) is
chassis ground.
Max. 1
Turn starting
NO
switch OFF.
Disconnect T01, E1.
T01 (female) (12) is
chassis ground.
ET-31 Related electrical circuit diagram

20-194
(8)
Remedy
Defective rotary switch

(Abnormality in photointerrupter)
Replace
controller
Repair or
replace
harness between T01
(female) (11) and E1
(female) (12)
Repair or
replace
harness between T01
(female) (12) and E1
(female) (13)
Repair or
replace
023502
Cause
TROUBLESHOOTING
ET-32
ET-32 [C5] (Abnormality in totary switch photo-interrupter) is displayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause
3 YES
Is resistance
YES between T01
(female) (5), E3
2
(female) (26) and
Is resistance
chassis normal?
YES between T01
Min. 1 M
NO
(female) (4), E3
Turn starting
(female) (33) and
1
switch OFF.
chassis normal?
Disconnect T01, E3.
Is resistance
Min.
1
M
between T01
Turn starting
(female) (3), E3
NO
switch OFF.
(female) (25) and
Disconnect T01, E3.
chassis normal?
023502
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
6 YES
from A
Is resistance
YES between T01
(female) (8), E3
5
(female) (35) and
chassis normal?
Is resistance
YES between T01
Min. 1 M
NO
(female) (7), E3
Turn starting
(female) (27) and
4
switch OFF.
chassis normal?
Disconnect T01, E3.
Is resistance
Min. 1 M
between T01
Turn starting
(female) (6), E3
NO
switch OFF.
(female) (34) and
Disconnect T01, E3.
chassis normal?
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
9 YES
Is resistance
YES between T01

7
from B
When E3 is
resistance between
8
T01 (female) (3) and
(4) normal?
Min. 1 M
NO
(female) (10), E3
Turn starting
(female) (36) and
switch OFF.
chassis normal?
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
Is resistance
between T01
(female) (9), E3
(female) (28) and
chassis normal?
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
Remedy
to A

in wiring harness between
T01 (female) (5) and E3
(female) (26)
Repair or
replace

(female) (33)
Repair or
replace

(female) (25)
Repair or
replace
to B

(female) (35)
Repair or
replace

(female) (27)
Repair or
replace

(female) (34)
Repair or
replace
to C
Defective contact in wiring
harness between T01
(female) (3) and E3
harness between T01
(female) (4) and E3
(female) (33)
(female) (36)
(female) (28)
Repair or
replace
Repair or
replace
Repair or
replace
20-195
(8)
TROUBLESHOOTING
ET-32
Cause
When E3 is
10
from C
When E3 is
disconnected, is
resistance between
(5) normal?
resistance between
(6) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
15 YES
When E3 is
resistance between
14
(10) normal?
13
from D
When E3 is
disconnected, is
resistance between
(8) normal?
resistance between
(9) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
When E3 is
resistance between
17
(7) normal?
16
from E
When E3 is
disconnected, is
resistance between
(5) normal?
resistance between
(6) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
When E3 is
19
from F
When E3 is
disconnected, is
resistance between
(8) normal?
resistance between
(9) normal?
(8)
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
20-196
When E3 is
resistance between
20
(10) normal?
Repair or
replace
Repair or
replace
Repair or
replace
to E
harness between T01
(female) (3) and E3 (female)
(25) and wiring harness
between T01 (female) (10)
harness between T01
Repair or
replace
Repair or
replace
Repair or
replace
to F
harness between T01
harness between T01
harness between T01
21 YES

harness between T01

harness between T01
18 YES
When E3 is

harness between T01

harness between T01
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
When E3 is
to D
Repair or
replace
Repair or
replace
Repair or
replace
to G
harness between T01
harness between T01
harness between T01
Repair or
replace
Repair or
replace
Repair or
replace
023502
12 YES
When E3 is
resistance between
11
(7) normal?
Remedy
TROUBLESHOOTING
ET-32
Cause
24 YES
When E3 is
When E3 is
resistance between
23
(8) normal?
22
from G
When E3 is
disconnected, is
resistance between
(6) normal?
resistance between
(7) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
27 YES
When E3 is
When E3 is
resistance between
26
(7) normal?
25
023502
from H
When E3 is
disconnected, is
resistance between
(9) normal?
resistance between
(10) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
30 YES
When E3 is
resistance between
29
(10) normal?
28
from I
When E3 is
disconnected, is
resistance between
(8) normal?
resistance between
(9) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
33 YES
When E3 is
31
from J
When E3 is
disconnected, is
resistance between
(8) normal?
When E3 is
resistance between
32
(10) normal?
resistance between
(9) normal?
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.

harness between T01
Repair or
replace
Repair or
replace
Repair or
replace
to I
harness between T01
harness between T01
Repair or
replace
Repair or
replace
Repair or
replace
to J
harness between T01
harness between T01
harness between T01
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.

harness between T01

harness between T01
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
When E3 is
to H

harness between T01
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
Remedy
Repair or
replace
Repair or
replace
Repair or
replace
to K
harness between T01
harness between T01
harness between T01
Repair or
replace
Repair or
replace
Repair or
replace
20-197
(8)
TROUBLESHOOTING
ET-32
36 YES
When E3 is
When E3 is
resistance between
35
(10) normal?
34
from K
When E3 is
disconnected, is
resistance between
(9) normal?
resistance between
(10) normal?
Min. 1 M
Turn starting
NO
switch OFF.
Disconnect T01, E3.
Min. 1 M
Turn starting
switch OFF.
NO
Disconnect T01, E3.
ET-32 Related electrical circuit diagram

20-198
(8)
Min. 1 M
NO
Turn starting
switch OFF.
Disconnect T01, E3.
Remedy
Defective rotary switch

(Abnormality
in photo-interrupter)
Replace

harness between T01
Repair or
replace

harness between T01
Repair or
replace

harness between T01
Repair or
replace
023502
Cause
TROUBLESHOOTING
STANDARDS
TABLE
FOR MEASURING
OF FAILURE
HYDRAULIC
H-l
MODES
PRESSURE
Abnormal
H-2
Relief
H-3
Hydraulic
noise
sound
HYDRAULIC
AND
is made
is heard
(from
(when
oil overheats
Work
equipment
does
Work
equipment
is slow,
There
Steering
H-8
Turning
H-9
Feeling
(work
(work
is excessive
wheel
equipment
speed
when
when
lacks power
at neutral)
POSITIONS..
drift
20-204
............................................
20-206
.............................................................................................
20-208
..................................................................................................
20-208
..............................................................................................
control
lever is operated
(steering
at neutral). ..........................
...........................................................................................................
of work
equipment
.................................................................................
.20-208
20-209
20-210
20-21 1
............................................................................................................................
20-21 1
lacks power
at neutral)
operating
pump)
MOUNTING
.20-202
not turn
is slow,
equipment
FILTER
not operating)
not move
hydraulic
does
AND
around
SYSTEM
PRESSURE, AND JUDGEMENT

VALUES .................................
............................................................................................................
not operating)
(when
H-4
H-6
CAUSES
MEASUREMENT
H-5
H-7
CHART FOR HYDRAULIC

(H MODE)
............................................................................................................................
wheel is strange.. .....................................................................................
steering
20-212
20-212
20-201
0
STANDARDS
FOR MEASURING
HYDRAULIC
PRESSURE, AND JUDGEMENT
VALUES
TROUBLESHOOTING
STANDARDS
JUDGEMENT
FOR MEASURING
VALUES
HYDRAULIC
PRESSURE, AND
Unit:
T
No.
Posture
for
machine
Measurement
Judgement
this range
conditions
values (any value

indicates
a failure)
PM (main
oressure)
Ps (steering
pressure)
*a=
All work
Work
outside
PP (pilot
pressure)
equipment
at standard
MPa (kg/cm*)
Min.
position.
1.0 (IO),
and
equipment
not operated.
Min.
2.0 (201,
and
Max. 2.0 (20)
+ 2.5 + 251
Pp+ 1.0 ( + 101
235FO21025
:Hm
Steering
cylinder
relief.
16.2 - 18.1
(165 - 185)
Vlax. Ps + 2.5
(25)
%I
PSI & 1.0 (IO)
23.0 - 26.0
(235 - 265)
%I
PSI + 1.0 (IO)
23.0 - 26.0
(235 - 265)
235FO2107
Left blade
lift cylinder
relief.
235FO2108
n
l
Right
blade
lift cylinder
relief.
235FO2109
l
Front
wheels
raised
off
ground.
l
Steering
Operating
1 turn/2
235FO2110
1.
The oil temperature
2.
Measure
within
3.
With
with
shall
Max.
5.9 (60)
Vlax. 6.4 (65)
PQ5
t-205
speed:
sec.
be 45 - 55C.
engine
speed
at both
low
idling
and
high
idling,
and check
that
both
measurements
are
the standard.
the CLSS, the hydraulic
reason,
pressures
put the measurement
are within
El
the
operated.
the specified
PSI is the measured
at different
data into a formula
points
are mutually
for calculating
related
the judgement
and change
standard,
together.
For this
and check that they
range.
data
marked*.
To hydraulic
control
valve
PS
\
To steer
ir
valve
20-202
0
235COO2220
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
Parts causing
Failure
Does
20-204
0
Pump
Surge
pressure
absorb-
Priority
divider
flow
valve
mode
not move
Slow,
P
E
8
failure
Turning
lacks power
speed
is slow,
lacks power
Changes
Feeling when
operating
steering
wheel is strange
between
There
is kickback
There
is a grating
00
being
feeling
heavy
and light
I
io
I
do
I
4
I
Q
0
0
0
0
I
in
I
A
023502
equipment
control
link
Troubleshooting
code
Shuttle valve for circle rotation
Slip clutch
Wrk
o
gear (%I)
HYDRAULIC PRESSURE MEASUREMENT AND

FILTER MOUNTING POSITIONS
TROUBLESHOOTING
PRESSURE MEASUREMENT
HYDRAULIC
POSITIONS.
AND FILTER MOUNTING
Fia 1
0
Measuring
port for work
main
equipment
oil pressure
Priority
divler
(PM).
l
Measuring
port for steering
oil pressure
(Ps).
flow
valve
\
PM
Ps
( _______~______t___i_-______
235CD02221
Fia 2
pressure
Pilot
LS line
filter
measuring
port
(PP).
Surge Dressure
valve
absorbing
(3).
235COO2222
b@-+@A
Fig 3
.
Pump
filters
Filters
(41, (5),
(I),
(2).
Fig 4
(6) on top of surge
pressure
absorbing
valve.
absorbing
20-206
0
valve
235CDO2044
HYDRAULIC PRESSURE MEASUREMENT AND

FILTER MOUNTING POSITIONS
TROUBLESHOOTING
Fig 5
0
Control
valve
filters
(71, (8).
Control
Valve
R.H.
COntrOl
Valve
L.H
235C00204E
Fia 6
l
Steering
valve
LS line filter
(9).
Fig 7
Measuring
(Serial
No.:
port for
brake
piston
(circle)
pressure.
11001 - 12050)
20-207
0
H-l,
TROUBLESHOOTING
H-l
Abnormal
noise is made (from around pump).

Remedy
Cause
YES
Is strainer
clogged?
YES
3
-
I;
H-2, H-3
raulic tank
el normal?
Is problem
corrected when
- piping between
NO tank and pump is
tightened?
~
NO
4YE
Zlogged strainer.
Clean
_ooseness of piping
:lamp.
Tighten
Iefective
Replace
pump.
Are metal
particles found
w,hen hydraulic
011 IS drained?
N(
Natch for a short time to

;ee if there is any change
n the condition.
Inspect again
[according to
change in
condition).
_ack of oil.
Add hydraulic
oil.
Zlogged orifice.
Clean
Zlogged steering LS line

ilter (9) (See Fig. 6).
Clean
H-2 Relief sound is heard (when not operating).

1)
From priority
Is LS port orifice
clogged?
flow
divider
valve.
H
NO
2)
From surge
pressure
absorbing
valve.
Clogged spool orifice of

priority flow divider
valve.
H-3 Hydraulic
1 YES
oil overheats
(when not operating).

Clogged steering LS line
filter (9) (See Fig. 6).
Clean
Defective operation
servo valve.
Repair or
replace.
Is pilot line oil

pressure high?
. Priority flow
divider valve is
being relieved.
* Steering oil
pressure is
high.
[I72 MPa
(175kg/cm?l
20-208
0
NO
of
H-A
TROUBLESHOOTING
H-4
Work equipment
at neutral).
does not move when control lever is operated
Cause
I)
No work
equipment
(steering
Remedy
moves.
YES
Go to Item 2).
1
Is hydraulic
pump main preSsure normal?
YES
24.5 + 1.5 MPa

(250+15
NO
kg/cm)
Is pilot oil pressure normal?
YES
3
$5, MPa
Is surge pressure
absorbing valve
LS line filter
clogged?
(_$ kg/cm*)
Main oil
pressure
NO
4 YE
Does condition
Check filter (3).
_ become normal
NO when servo valve
(See Fig 2)
is replaced?
- Check
operation
spool.
2)
Work
equipment
for control
Pump filter (1) or (2) is

clogged. (See Fig. 3)
Clean
Clogged filter (3). (See

Fig. 2)
Clean
Defective operation
servo valve.
Repair or
replace.
of
Repair or
replace.
N(
of
valve on one
side only does not move.
Is surge pressure
absorbing valve
filter clogged?
* Check filter (4)
N
or (6).
(See Fig 4)
2 YES
Work
equipment
NO
Clogged filter.
Iean
Defective operation
control valve.
of
lepair or
eplace.
Defective operation
control valve.
of
Repair or
replace.
for one line only does not move.

2 YES
NO
Is work
equipment
control link
normal?
- Check
operation
linkage?
Xean
Is control valve
filter clogged?
* Check filter (7)
or (8).
(See Fig 5)
3)
Clogged filter
Defective
cylinder.
Repair or
replace.
Defective
motor.
Repair or,
replace.
Defective
clutch.
adjustment
of
Circle
rotation ge
assembly
ES
of
4djust
normal?
Engine low
idling
become normal
Defective operation
shuttle valve.
of
qeplace
Defective operation
:ontrol valve.
of
qepair or
replace.
lefective
inkafge.
of
qepair or
.eplace.
5.gMPat6
kg/cm?
- Engine high
idling
: 8.8MPa (90
kg/cm*)
- Blade raised.
NC
operation
20-209
0
H-5
TROUBLESHOOTING
is slow, lacks power.
H-5 Work equipment
Remedy
Cause
I)
All work
equipment.
io to H-4.
2)
Work
equipment
valve on one side only.

jefective
Does condition
become normal
when relief valve
of control valve
is adjusted?
idjust
relief valve.
;o to H-4.
. Relief pressure
:24.5 t 1.5 MPa
(250 2 15 kg/cm)
3)
for control
NO
Work
equipment
for one line only.

hen slow
2 YES
Doescondition
1 Ibecome normal
when blade float
valve is
Blade lift
3epair or
eplace.
defective blade float

alve.
GotoA
* Engine: Rated
Is work
equipment
control linkage
normal?
. Check
operation
linkage.
([i%$Thift
Whenthereisnopower~
of
sot0
From IA
Is there defect
inside cylinder?
4 YES
i!ic$q1damage,
dirt.
sd?
* Check for oil
leakage.
* Defective relief
pressure setting
(only for
machines with
relief valve).
20-210
0
11
NO
H-4.
of
3epair or
.eplace.
Iefective
inkage.
operation
Defective
cylinder.
Repair or
replace.
Defective
valve.
pilot check
Repair or
replace.
Defective
control
Repair or
replace.
valve.
TROUBLESHOOTING
H-6
H-6, H-7
There is excessive
work equipment.
hydraulic
drift of
Remedy
Cause
1 YES
Are cylinder,
piston, seal
damaged?
Check for oil

leakage, damage.
H-7
NO
Damaged cylinder,
piston, seal.
Replace
Defective
valve.
pilot check
Repair or
reolace.
Defective
steering
?epair or
.eplace.
Defective
cvlinder.
steering
Steering wheel does not turn

(work equipment at neutral).
2 YES
YE
L Does
cylinder
move normally?
NO
- Is there any
internal defect?
YES
)
- 17.2 + 1.0 MPa
(175 + 10 kg/cm).
valve.
Clogged pump filters

(2). (See Fig.3)
Is pilot pressure
, normal?
<epair or
,eolace.
YES
(I),
Ilean
Clean
Clogged filter
at top and bottom

of surge pressure
- Steering oil
pressure
: _$$ Nm
k.
r
- Check filters
(3),(5). (See
Fig.2.4)
YES
1 pees condition
valve.
Repair or
reolace.
Defective
shuttle
Defective
servo valve.
Repair or
replace.
Defective
pump.
Repair or
replace.
5[ [
From A
shuttle
* Check
valve.
for dirt.
replaced?
- Check
operation of
spool.
* Check for dirt.
20-211
0
TROUBLESHOOTING
H-8, H-9
H-8 Turning speed is slow, lacks power

(work equipment at neutral).
Cause
YES
Remedy
Go to H-7
4 YE:
Defective
cylinder.
steering
Repair or
replace.
move normally?
YI
Is relief pressure
Go to H-7
Is relief pressure
of double relief
valve normal?
- 20.6
MPa
(210 kg/cm?
NO
Defective
valve.
double
relief
Defective priority
divider valve.
flow
Adjust or
replace.
. 17.2 ? 1.0 MPa

1175 + 10 kg/cm2)
10
H-9
I)
2)
3)
Feeling when operating

is strange.
Changes
There
There
20-212
0
between
being
Adjust or
replace.
steering wheel
heavy and light.
Defective steering
check valve.
CF line
?epair or
.eplace.
Defective steering
line check valve.
CF, LS
qepair or
.eplace.
Defective
valve.
7epair or
.eplace.
is kickback.
is a grating
feeling.
steering
023502
30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL. . . . . . . . . . . . . . . .30-1-2
COATING MATERIAL LIST . . . . . . . . . . . . . . . . . . .30-1-4
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . 30- 2
STARTING MOTOR
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 4
ALTERNATOR
NOZZLE HOLDER
FUEL INJECTION PUMP
WATER PUMP
ENGINE OIL COOLER CORE
TURBOCHARGER
AIR COMPRESSOR
CYLINDER HEAD
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 15
ENGINE (INCL. TRANSMISSION)
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 23
RADIATOR
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 31
FUEL TANK
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 34
PTO
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 41
TRANSMISSION
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-45-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-45-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 54
TRANSFER
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 69
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 72
TRANSMISSION CONTROL VALVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 78
HYDROSHIFT TRANSMISSION PUMP
TANDEM AND FINAL DRIVE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 83
FINAL DRIVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 85
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 94
BEVEL GEAR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
BEVEL PINION
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
FRONT AXLE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
STEERING VALVE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
WHEEL BRAKE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
AIR TANK
Removal and Installation . . . . . . . . . . . . . . . . . . 30-137
HYDRAULIC TANK
HYDRAULIC PUMP
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
MAIN CONTROL VALVE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
CIRCLE ROTATION MOTOR
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
DRAWBAR SHIFT CYLINDER, BLADE
LIFT CYLINDER, LIFTER GUIDE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
ARTICULATE CYLINDER
REAR MOUNT RIPPER CYLINDER
HYDRAULIC CYLINDER
Serial No. 11001 12502
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
Serial No. 12503 and up
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 30-205-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205-5
CIRCLE ROTATION GEAR AND
HYDRAULIC OIL MOTOR
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
30-1
(6)
30-1-1
(6)
30-215
30-216
30-217
30-219
30-224
30-225
30-226
30-228
30-229
30-223
30-238
30-241
30-243
30-246
023502
BLADE
Removal and Installation . . . . . . . . . . . . . . . . . .
CIRCLE AND DRAWBAR
Removal and Installation . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR MOUNT RIPPER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METHOD FOR LIFTING UP ROPS CAB . . . . . . . .
INSTALLATION OF ROPS . . . . . . . . . . . . . . . . . . .
ROPS cab
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCONNECTION AND CONNECTION
OF ARTICULATE SECTION
Serial No. 11001 12502
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to read this manual

1.
(Rev. 2009.01)1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
r e m o v a l o r in s ta l l a t i o n o f pa r ts a r e
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
q
: Precautions related to work safety

: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished
Sketches of special tools

Various special tools are illustrated for the local
manufacture.
30-1 (7)
2.
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Disassembly
q
In Disassembly section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

6 : Amount of oil or coolant drained
Assembly
q
In Assembly section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished
Sketches of special tools

q
Various special tools are illustrated for the local
manufacture.
30-1 (7)
Coating materials list
(Rev. 2009.02)
1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
023502
790-129-9140
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
790-129-9080
LG-6
790-129-9160
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
419-15-18131
100 g
30-1-4
(6)
Molybdenum
disulfide
lubricant
Grease
790-129-9310
200 g
Tube
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
(6)
Container
Used for rough surfaces such as the circle gear

top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.
30-1-5
Q'ty
LG-9
ThreeBond
1206D
LM-P
Seizure
prevention
compound
Part number
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microCan
organisms, animals, and plants.
023502
Gasket sealant
CateKomatsu code
gory
G2-U-S
ENS grease
427-12-11871
SUNSTAR
PAINT PRIMER
580 SUPER
Caulking material
Adhesive
023502
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
SUNSTAR
PAINT PRIMER
435-95
Q'ty
Container
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
2 kg
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S
ThreeBond
1855
Part number
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
30-1-6
(6)
SPECIAL TOOL LIST

Symbol
Parts No.
790-331-1110
C
D
Installation of cylinder
head
Disassembly, assembly
of transmission assembly
of final drive assembly
of hydraulic cylinder
Part Name
Qty
Remarks
Wrench
For tightening cylinder head angle
799-301-1500
Leak tester
For checking operation of piston
792-571-1600
Chain puller
For securing chain
790-502-1003
Repair stand
790-502-2000
Repair stand
790-101-1102
Pump
790-330-1100
Wrench
Removal, installation of round

head
790-302-1270
Socket (50 mm)
Leaning (*1)
790-302-1290
Socket (60 mm)
Leaning (*2)
790-102-1320
Socket (70 mm)
790-102-1330
Socket (75 mm)
790-302-1340
Socket (80 mm)
790-201-1702
Push tool Kit
790-101-5021
Grip
01010-50816
Bolt
790-201-1741
Push tool
Steering
790-201-1751
Push tool
Leaning (*1)
790-201-1761
Push tool
Leaning (*2)
790-201-1781
Push tool
Drawbar shift
Stand for disassembling cylinder
Blade lift
Drawbar shift
Blade shift
Power tilt
Articulate
Removal,
installation of
nylon nut
Ripper
023502
Nature of work
(*1) Serial No.: 11001 12050

(*2) Serial No.: 12051 and up
30-2
(6)
790-201-1791
Push tool
Blade lift
Blade shift
Power tilt
Articulate
790-201-1811
Push tool
Ripper
Press fitting
coiled bushing
Nature of work
Symbol
Parts No.
Part Name
Qty
Remarks
790-201-1500
Push tool KIT
790-101-5021
Grip
01010-50816
Bolt
790-201-1550
Plate
Steering
790-201-1560
Plate
Leaning (*1)
790-201-1570
Plate
Leaning (*2)
790-201-1590
Plate
Drawbar shift
790-201-1610
Plate
Blade lift
Blade shift
Power tilt
Articulate
790-201-1620
Plate
Ripper
790-702-1000
Expander
796-720-1630
Ring
07281-00709
Clamp
796-720-1650
Ring
07281-01019
Clamp
796-720-1650
Ring
07281-01159
Clamp
796-720-1670
Ring
07281-01279
Clamp
796-720-1680
Ring
07281-01589
Clamp
791-560-1520
Floating seal installer
of hydraulic cylinder
Press fitting
dust seal
023502
Steering
Leaning
Blade lift
Blade shift
Drawbar shift
Installation of
piston ring
Power tilt
Articulate
Ripper
Disassembly, assembly of
circle rotation gear and
hydraulic motor assembly
Installation of floating seat
(*1) Serial No.: 11001 12050

30-3
(6)
REMOVAL OF STARTING
ASSEMBLY
Disconnect
the
cable
from
the
MOTOR
negative
(-)
ter-
minal of the battery.

1.
Disconnect
connector
2.
Disconnect
wiring
3.
Remove
starting
(1).
(2).
motor
assembly
(3).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
l
Carry
out
installation
in the
reverse
order
to
remo-
val.
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 11001 - 12000
Disconnect
the
cable
from
the
negative
(-)
ter-

Disconnect
Remove
mount
Move
then
3 alternator
bolt
(2)
wires
of
(1).
adjustment
plate,
then
loosen
bolt and nut (3).

alternator
loosen
alternator
Remove
assembly
belt
tension,
(4) towards
and
cylinder
remove
belt
block,
(5) from
assembly.
mount
nator assembly.
bolt
and
nut
(3), then
remove
alter-
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 11001 - 12000
l
Carry
out
installation
in the
reverse
order
to
remo-
val.
Adjust
the fan belt tension.
For details,
judgement
30-4
0
see TESTING
standard
value.
AND
ADJUSTING,
table
of
DISASSEMBLY
ALTERNATOR
AND ASSEMBLY
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial
No.: 12001 and up
Disconnect the cable from the negative

1.
Open engine
2.
Disconnect
3.
Remove locknut (3), and turn

(4), then remove V-belt (5).
4.
(-) ter-
side cover.
alternator
wiring
(1) and (2).
adjustment
nut
m
Remove mounting
bolts (6) and
move alternator assembly (8).
(7), then
re-
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial
No.: 12001 and up
Carry out
removal.
installation
in the
reverse
order
to
m
t
After installing the V-belt, adjust the tension

of the belt.
For details, see TESTING AND ADJUSTING,
Testing and adjusting of belt tension.
30-4- 1
0
REMOVAL OF NOZZLE HOLDER

ASSEMBLY
1.
Remove
(I),
air
engine
hood,
cleaner
then
remove
assembly
(2),
and
muffler
assembly
intake
connector
(3).
2.
Disconnect
3.
Remove
cover
4.
Loosen
locknut
5.
Remove
connector
6.
Remove
holder
7.
Use a slide
10 mm,
delivery
tube
(5). m
(6). m
(7).
(8).
hammer,
Pitch
(4).
or screw
1.5 mm),
in bolt
then
(Thread
remove
nozzle
dia. =
holder
(9) using a bar.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
l
Carry
out
installation
in the
reverse
order
to
remo-
val.
Sleeve
nut:
23.5 i
Mounting
bolt:
Locknut:
36.8 12.5
Connector:
Mounting
1.0 Nm (2.4 + 0.1 kgm)
12
4.9 + 1.0 Nm (0.5 i
0.1 kgm)
m
Nm (3.75 k 0.25 kgm)
m
36.8 + 2.5 Nm (3.75 + 0.25 kgm)
bolt:
66.2 k 7.4 Nm
(6.75 i
30-4-2
0
0.75 kgm)
REMOVAL OF FUEL
INJECTION PUMP ASSEMBLY
1.
2.
Open engine
Remove
tation
*
right side cover.
oil gauge
guard
When
pipe
removing
the
not to let the spacer

3.
Remove
coupling
and disconnect
4.
5.
Disconnect
flange
fuel
rotation
guard,
lock
bolt
(4), then
control
rod
Disconnect
hoses
(9), (IO), and
fuel
careful
bolt
(5),
(II),
motor
cable
and fuel
re-
(12) and (13).
lubrication
Remove
jection
be
remove
(6) and stop
(8).
Remove
ro-
spring
hoses
(2), and
on the inside fall out.
coupling.
nect 6 fuel injection

7.
hose
(7), and remove
turn
6.
(I),
(3).
tubes
4 mounting
pump
(14) and
pipes (16).
bolts
assembly
(15), and
discon-
(17), then
remove
fuel
in-
(18). m
kc
:
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
l
Carry
out
installation
in the
reverse
order
to
remo-
val.
Coupling
lock bolt:
78.5 f 4.9 Nm
(8 i
0.5 kgm)
Lubrication
tube
(14):
29.4 i 4.9 Nm
Lubrication
tube
(15):
22.5 i
(3 _C0.5 kgm)
2.9 Nm
(2.3 + 0.3 kgm)

m
Fuel injection
pipe sleeve
nut:
23.5 k 1.0 Nm
(2.4 + 0.1 kgm)
Adjust
For
fuel injection
details,
see
ing fuel injection
timing.
TESTING
timing.
AND
ADJUSTING,
Adjust-
DISASSEMBLY
AND ASSEMBLY
WATER
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain
engine
cooling
water.
2. Disconnect 2 hoses (2) and 2 connectors

washer tank (I).
3. Disconnect hose (5) and connector
voir tank (4).
4. Remove
together
6. Disconnect
7. Remove
(6) of reser-
washer tank (I) and resevoir

with mounting bracket (7).
5. Remove alternator assembly

For details, see REMOVAL
ASSEMBLY.
(3) of
tank
(4)
(8).
OF ALTERNATOR
Serial No.: 11001 - 12000
hoses (9), (IO), and (II).
tube (12) and connectors
(13).
Serial
8. Pull out spring (14), then twist tube (15) with a

bar and push up.
9. Remove
bolt (161, then remove
pulley (17).
10. Remove mounting bolts (181, then remove

ter pump assembly (19).
30-6
0
wa-
No.: 12001 and UD
PUMP
DISASSEMBLY
WATER PUMP
AND ASSEMBLY
INSTALLATION OF WATER
PUMP ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
Adjust the tension of the alternator belt.

For details, see TESTING AND ADJUSTING,
justing belt tension.
Ir
to
Ad-
Refilling with water

Add water through water filler to the specified
level.
Run the engine to circulate the water through
the system. Then check the water level again.
30-7
0
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
1.
2.
Drain engine
Disconnect
washer
3.
cooling
2
water.
hoses
(2)
and
connectors
(3)
of
tank (1).
Disconnect
hose
(5) and
connector
(6) of
reservoir
tank (4).
4.
5.
Remove
washer
tank
together
with
Remove
turbocharger
exhaust
muffler
(1)
mounting
and
bracket
lubrication
drain
tube
reservoir
tank
(4)
(7).
(9),
return
then
tube
(8) and
remove
tube
(IO).
6.
Remove
engine
oil cooler
7.
Remove
4 nuts (12), then
assembly
remove
(11).
cooler
core (13).
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY
l
Carry
out
installation
in the
reverse
order
to
remo-
val.
Refilling
with water
Add water
*
Run
the
through
engine
water
to
filler to the specified
circulate
the
water
level.
through
the
system.
Then check the water
%
Engine
cooling
level again.
water:
Approx.
58 Q
235FO2204
REMOVAL OF TURBOCHARGER
ASSEMBLY
1.
Remove
hood assembly
For details,
see
and air cleaner.
REMOVAL
OF NOZZLE
HOLDER
AS-
remove
inlet
SEMBLY.
2.
Disconnect
connector
3.
dust
Remove
muffler
(6) and connector

4.
indicator
hose
(3), then
(4).
Disconnect
assembly
(5),
then
remove
elbow
(7).
clamp
(8),
then
remove
inlet
connector
(8).
5.
Disconnect
6.
Remove
(12).
hose (IO), and drain tube
mounting
bolts
and
turbocharger
(i 1).
assembly
INSTALLATION OF
TURBOCHARGER ASSEMBLY
supply
Carry
out
installation
in the
reverse
order
to
remo-
val.
m
*
Fit the gasket

m
with
Mounting
UP
mark facing
up.
bolt:
66.2 & 7.4 Nm

(6.8 k 0.8 kgm)
3%9
REMOVAL OF AIR COMPRESSOR

ASSEMBLY
A
1.
Loosen
Remove
drain valve
engine
(2), then remove

2.
Disconnect
tubes
3.
4.
oil
and drain air tank pressure.
gauge
rotation
air hoses
pipe
guard
(4) and
(1) and
hose
flange
remove
water
remove
water
(3).
(5), and
(6) and (7).
Remove
corrosion
Remove
air
hose (8).
tubes
(9) and
(IO),
then
tube (11).
5.
Remove
pressor
lubrication
INSTALLATION
COMPRESSOR
l
Carry
val.
30-&o
tube
(12), then
remove
air com-
(13).
out
installation
OF AIR
ASSEMBLY
in the
reverse
order
to remo-
REMOVAL OF CYLINDER
HEAD ASSEMBLY
1.
Draining
cooling
water
Loosen drain valve
2.
Side covers,
hood
1)
Remove
precleaner
2)
Open
R.H.
cover
hinge,
3)
3.
(1) and drain
Remove
Air cleaner
side
and exhaust
cover
then remove
assembly,
2)
Remove
inlet connector
Remove
mounting
4)
Remove
water.
pipe (2).
disconnect
hood
L.H.
side
(4) as one unit.
(5).
inlet connector
Disconnect
assembly
(3),
L.H. and R.H. covers
1)
3)
cooling
KOMA-CLONE
band,
pipe at flange
mounting
then
(6) end.
bolts (7).
remove
air cleaner
(8).
inlet
as one unit.
connector
(9) together
with
bracket
5.
Inlet connector,
1)
6.
clip (13).
2)
Remove
mounting
3)
(15).
Disconnect
electric
take heater
(18).
Corrosion
1)
2)
3)
7.
air intake
Remove
resistor
Remove
bolts
(14) and
wiring
assembly,
(16),
inlet
(17)
connector
and
air
in-
tube
hoses (19) and (20).
Remove
mounting
assembly
(21).
Disconnect
tubes
bolts,
and
corrosion
resistor
(22).
Fuel, oil filter assembly

1)
Disconnect
2)
Disconnect
3)
Remove
fuel hoses (23) and (24).

oil tubes
mounting
and oil, fuel filter
8.
heater
Intake
bracket
mounting
bolts
3022
bolts,
assembly
then
remove-
bracket
(27) as one unit.
manifold
Remove
(30). m
(25) and (26).
mounting
(29)
and
bolts
intake
(28),
then
manifold
remove
assembly
9.
Turbocharger,
exhaust
Disconnect
and drain tube

Remove
ifold,
bolts
2 -
remove
(33)
of
and remove
turbocharger
hose
(31)
exhaust
man-
remaining
and
exhaust
bolts.
manifold
(34) as one unit.

Turbocharger,
& ks
supply
3 bolts in position.
Sling turbocharger
assembly
assembly
oil
(32).
mounting
leaning
Then
manifold
turbocharger
assembly:
Remove
tube
10. Fuel injection
exhaust
manifold
40 kg
(35).
tube, fuel spill tube
1)
Remove
6 fuel injection
2)
Remove
spill tubes
tube
(36).
(37).
z
4
2
11. Head cover
Remove
cover
mounting
12. Rocker arm assembly

Remove
mounting
lever assembly
*
bolts
(38)
then
remove
head
(39).
When
m
bolts
(40)
then
remove
rocker
lever,
loosen
screw
(43)
rocker
(41).
installing
then
turn
adjustment
times
to prevent
strain
locknut
back
on the push rod.
(42),
2 -
13. Holder
Remove
mounting
bolts
(44),
then
remove
holder
(45).
14. Connection
Loosen
lock
nut
(46),
then
@ (Thread
dia.
remove
connection
(47)
and pull out.
15. Nozzle
Using
holder
bolt
ng
mm), remove
*
Check
10
mm,
Pitch
1.5
nozzle holder (48).
that there
is a gasket
fitted
to the tip of
the nozzle holder.

16. Push rod
Remove
push rod (49).
17. Rocker arm housing

Remove
mounting
)
bolts
(50)
then
remove
rocker
arm housing (51).

18. Crosshead
Remove
19. Cylinder
1)
crosshead
(52).
head assembly
Remove
mounting
der head assembly

2)
Remove
3064
gasket (55).
m
bolts
(54).
(53) then
remove
cylin-
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
.
Carry
out
installation
in the
reverse
order
to
remoIntake
val.
Tighten
the
shown
intake
manifold
in the
order
(1 -
manifold
24)
in the diagram.
Intake
manifold
mounting
bolt
21
17
13
12
16
20
24
235FO2205
Tighten
the
shown
in the
the order
w
exhaust
manifold
diagram,
(4 -
then
Exhaust
manifold
mounting
(1 -
3)
remainder
in
Exhaust
manifold
the
bolt
29.4 * 4.9 (3.0 + 0.5)
2nd
Install
order
the
24).
1st
in the
tighten
7 17
66.2 + 7.4 (6.8 k 0.8)
gasket
with
the
OUT
mark
facing
20 2
1 13
16 6
3 21
2412
the
outside.
I
m
Sleeve
nut:
Spill tube joint
566FO6352
4.9 f 1.0 Nm (0.5 + 0.1 kgm)

bolt:
8.8 f 1 .O Nm
(0.9 + 0.1 kgm)
Head cover
mounting
bolt:
4.9 k 1.0 Nm (0.5 + 0.1 kgm)

m
*
Clean the oil hole of the mounting
Check that the ball of the adjustment

curely
in the socket
Rocker
bolt and install.

screw
is fitted
se-
of the push rod.
arm mounting
bolt:
98.1 k 4.9 Nm (10 + 0.5 kgm)

w
Adjustment
screw
locknut:
48.0 k 2.9 Nm (4.9 + 0.3 kgm)

*
Adjust
the valve
For details,
valve
AND ADJUSTING,
Adjusting
clearance.
Set one
rocker
clearance.
see TESTING
side
of holder
arm housing
on head
of mounting
bolt
or
and tighten.
30-&w
*
*
Connection:
Locknut:
Check
that
holder
sleeve.
37.2 + 2.9 Nm (3.8 + 0.3 kgm)

63.7 k 4.9 Nm (6.5 f 0.5 kgm)
there
Check that there
is no dirt
or dust
is a copper
gasket
inside
fitted
the
nozzle
to the tip of
the nozzle holder.
Rocker
arm housing
mounting
bolt:
98.1 * 4.9 Nm (10 f 0.5 kgm)
pi?icJ
*
Adjust
i)
ii)
iii)
iv)
the crosshead
Loosen
Hold
locknut
down
as follows.
and turn
top
tighten
adjustment
When
adjustment
tighten
a further
Tighten
locknut
302 6
Locknut:
back adjustment
surface
of crosshead
screw.
lightly
and
screw.
screw
contacts
valve
20.
to hold in position.
58.8 i
5.9 Nm (6.0 +_ 0.6 kgm)
stem,
Check
der
there
is no dirt
mounting
or dust
surface
on the
cylin-
or
inside
the
cylin-
does
not
come
der.
*
*
that
head
Check
that
when
installing
the gasket.
Coat
the
threads
the
bolt
pletely
with
Screw
in the
3 turns
grommet
and
molybdenum
by
cylinder
hand,
seat
surfaces
disulphide
(LM-P).
head
then
mounting
tighten
out
com-
bolts
as shown
2 in the
diagram.
&
Mounting
bolt:
Anti-friction
621 OF301
compound
(LM-P)
w
Cylinder
head mounting
bolt:
The first time:
147.1 I 9.8 Nm
The second
215.7 + 4.9 Nm
The third
(15 I 1 kgm)
time:
(22 + 0.5 kgm)

1)
time:
When
using tool B
Use an angle tightening
wrench
and tighten
go+30
When not using tool B
2)
Make
marks
on the bolt and head with
pen, then tighten

+
Tighten
566FO6353
a felt
the bolt 90::
bolt 0 to 66.2 i
7.4 Nm
(6.75 + 0.75 kgm).

*
After
tightening,
bolt
head
to
make
indicate
one
the
punch
number
the bolt has been used.

.
If any bolt has 5 punch
it. Replace
Charging
Refilling
Refill
engine
it with
air conditioner
marks,
mark
on
of times
do not
the
Put mark on the bolt

and cylinder head
that
reuse
a new bolt.
with
gas.
with water
with
water
to circulate
F621201067A
to the
specified
the water
through
level,
and
run
the
the system.
level again.
Make mark with punch
F621201061
3027
DISASSEMBLY
AND ASSEMBLY
ENGINE
REMOVAL OF ENGINE
ASSEMBLY
(Incl. TRANSMISSION)
1.
Remove
mission
-
2.
3.
drain
case.
plug
Transmission
(I) and drain
oil from
case: Approx.
Radiator assembly
Remove radiator
assembly.
For details,
see REMOVAL
SEMBLY.
Lift up cabin.
For details, see METHOD
CAB.
trans-
25 f?
OF RADIATOR
FOR LIFTING
AS-
UP ROPS
4.
Air tank assembly

Remove air tank assembly.
For details, see REMOVAL OF AIR TANK ASSEMBLY.
5.
Hydraulic tank assembly

Remove hydraulic
tank assembly.
For details, see REMOVAL OF HYDRAULIC
ASSEMBLY.
TANK
P
Serial
6.
Wiring piping, control

Serial No.: 11001 - 12012, 12016 - 12018
1) Disconnect speed control wire (2) from transmission.
-+ Turn cap A and completely
loosen the
thread before disconnecting.
*
Ring B does not turn. If you attempt
to
turn it by force, you will damage
the
wiring harness.
(31, (3A), (4), (4A), and
2) Disconnect connectors
3)
4)
(5)
Remove
Remove
clip (6).
ground connection
Connector
Connector
Connector
30-18
0
(2A):
FW,
(39):
(40):
(41):
235FO2206
No.: 11001 - 12012,
Wiring harness end
(7).
RE, HI, LO, Ist, 2nd, 3rd, 4th

TM1 1
TM10
TM95
Serial
12016 - 12018
Alignment grove
I
Serial No.: 12013 - 12015, 12019 and up

Disconnect
connectors
(2A), (391, (401, and
(41).
Connector
solenoid valve end

TWG00248
No.: 12013 - 12015,
12019 and UD
DISASSEMBLY
5)
AND ASSEMBLY
ENGINE
Remove hose (9A) and wiring connectors

(IO) and (11) of radiator sub-tank (8) and
washer
tank (9), then remove
tank and
mounting bracket (12).
30-18-l
0
6)
Remove
cables
(13)
and
(14)
from
starting
motor.
I,
235FO2207
7)
Remove
inching
control
rod
(15)
frqm
trans-
mission.
235FO2208
8)
Remove
hoses
(16), (17), and
(18) from
hydraulic
pump.
9)
Remove
block
(19) from
frame.
335FO72OC
30&l 9
10) Remove
hoses (19A) and (19B).
w
11) Remove
12) Remove
air hose (19C).
drain
hose
(20) of engine
oil pan
from
from
com-
rear frame.
13) Remove
pressors
hoses
(23),
(21) and (22).
(24),
and
(25)
19A
235FO221C
14) Remove
15) Remove
accelerator
hoses
(27)
cable (26) from
and
(28)
engine.
from
final
drive
pump.
I
16) Remove
transmission
oil filler tube
(29).
235FO2212
8.
Mounting
Sling
bolts
engine
assembly
(32)
and
remove
mounting
bolts.
Engine
I?zlkg
1)
Remove
*
assembly:
transmission
Check
shims
the
2707 kg
from
number
(36) which
were
mounting
and
bolts (33).
positions
of
the
removed.
32
2)
Remove
*
engine
Check
the
shims,(37)
3)
Remove
*
engine
Check
shims
9.
the
front
mounting
number
which
were
and
(38) which
were
positions
and
3022
engine
the
of
the
nuts (35).
positions
removed.
235FO2213
Engine assembly
Remove
of
removed.
rear mounting
number
bolts (34).
assembly
(32) from
main frame.
INSTALLATION OF ENGINE ASSEMBLY

(Incl. TRANSMISSION)
1.
Engine assembly
Sling
engine
assembly
(32)
assembly:
2707 kg
and
set
to
main
frame.
Engine
& kg
t
If the
engine
installed,
ways
Sling
is raised
the
muffler
remove
engine
with
will
the
muffler
be damaged,
still
so al-
it.
assembly
and
install
mounting
bolts.
i)
Install
front
*
ii)
shim
Standard
Install
mounting
*
iii)
Install
bolts
(37)
bolts
tighten
and
4.1 mm
tighten
engine
front
(34).
(38)
bolts
transmission
(33).
shim thickness:
shim
Standard
and
shim thickness:
shim
Standard
mounting
*
(36)
mounting
and
3.1 mm
tighten
engine
rear
(35).
shim thickness:
4.1 mm
235FO2213
30623
3)
Adjust
shim
I .._.-.=-,,--/--~+=235COO2053
shaft coupling
Final drive input

shah coupling
i)
Insert
shims
that
the
allel
to
when
at
portions
center
the
line
final
supported
When
doing
ness
at
drive
by
this,
portions
BL,
of the
and
portions
the
BL
BR,
and
crankshaft
propeller
BL,
BR
shim
A.
thick-
shall
be
3.8
mm.
ii)
Decide
the
shim
ance at portion
iii)
Raise
the
engine
and
of shim
to
0.7
of
from
mm
0.5 mm
semble.
so that
the
clear-
C is 0 mm.
0.7 mm
add
30624
thickness
shim
of shim
transmission,
portion
and
C. Next,
portions
to
portion
iv)
add
remove
BL and
BR,
A, then
as-
Finally,
the
check
transmission
within
shaft
BR, and
standard
and
A so
is par-
that
the
and
misalignment
the
propeller
between
shaft
3 mm.
Tightening
torque:
D:
235.4 -
E:
245.2 -
411.9 Nm (24 - 42 kgm)

308.9 Nm (25.0 -
31.5 kgm)
F:
490.3 -
608.0 Nm (50.0 -
62.0 kgm)
G:
245.2 -
284.4 Nm (25 -
29 kgm)
H:
823.8 -
872.8 Nm (84 -
89 kgm)
is
2.
Drive shaft
Using
dial gauge,
face
runout
and
coupling
missible
of
face
value,
(31).
*
If they
check-again
coupling
are
at
Wiring,
runout
and
end
drive
end
are within
per-
install
drive
shaft
(30) with
bolts
not
within
mount
Mounting
bolt:
the
permissible
value,
ad-
shims again.
98.1 (10.0 -
3.
radial
transmission
at final
then
just the engine
that
face
122.6 Nm
12.5 kgm)
piping control
1)
Install transmission
2)
Connect
hoses
oil filler tube
(29).
(27) and (28) to final drive
pump.
3)
Connect
accelerator
235FO2.212
cable (26) to engine.
30625
4)
Connect
hoses
(23),
(24),
and
(25) to compress-
ors (21) and (22).
25
23
24
5)
Install
drain
hose
(20) of engine
oil
pan
to
rear
frame.
6)
Install
7)
Connect
block
(19).
hoses (19A) and (19B).
235FO2210
8) Connect
9) Connect
air hose (19C).
hoses
(16),
(17),
and
(18)
to
hydraulic
pump.
10) Connect
inching
11) Connect
cables
control
rod (15) to transmission.
(13) and (14) to starting
motor.
235FO22Oi
12) Install tank and mounting

bracket (12) to
rear frame, then connect connectors (IO) and
(II),
and hose (9A) to sub-tank
(8) and
washer tank (9).
13) Install ground
connection
(7).
14) Install clip (6).

15) Connect
connectors
(31, (3A), (4), (4A), and
(5).
Serial No.: 11001 - 12012, 12016 - 12018
16) Connect speed control wire (2) to transmission.
Set the connector facing 45 down to prevent water from getting inside the connector. Use a tie wrap to secure the wiring harness to prevent the slack in the
wiring from interfering with the frame.
Portion A must not interfere with the
frame.
Secure portion B with a band.
Serial No.: 12013 - 12015, 12019 and up
16) Connect connectors (2A), (39), (40), and (41).
Connector (2A):
FW, RE, HI, LO, Ist, 2nd, 3rd, 4th
Connector (39): TM1 1
Connector (40): TM10
Connector (41): TM95
4.
5.
6.
7.

Install hydraulic tank assembly.
For details, see INSTALLATION
TANK ASSEMBLY.
Air tank assembly
Install air tank assembly.
ASSEMBLY.
Cab
Lower cab.
Radiator assembly
Install radiator assembly.
ASSEMBLY.
30-28
0
I
Serial
235FO2206
No.: 11001 - 12012,
12016 - 12018
Serial No.: 12013 - 12015,
12019 and up
OF HYDRAULIC
OF AIR TANK
L
OF ROPS CAB.
OF RADIATOR
8.
Refilling with oil

1) Tighten drain plug.
2) Add engine oil through
specified level.
Q
*
Transmission
oil filler (29) to the
case: 35 e
Run the engine to circulate the water and oil

through the system. Then check the water
and oil levels again.
30-28-l
0
REMOVAL
1.
Loosen
OF RADIATOR,
drain valve
If the
coolant
(1) and drain

contains
coolant.
antifreeze,
dispose
of
ii
correctly.
u
Coolant:
58 P
235FO221
2.
Remove
hood
3.
Remove
piping
Remove
(2).
and electric
radiator
and aeration
Disconnect
Remove
hose
hose (5) from

hose (6) from
fan guard
Disconnect
wiring
inlet
heater
(3),
outlet
hose
(4)
engine.
sub tank (6A).
(7).
tubes
(8) and
(9) from
radia-
tor (10).
4.
Loosen
bolts (11) and remove
panel
(12).
30629
Sling
radiator
assembly
(13).
and
remove
mounting
bolts.
1)
Loosen
front
& kg
Radiator
mounting
bolts (14).
assembly:
183 kg
13
235COO2056
2)
Loosen
rear mounting
bolts
(15).
23x002057
6.
Raise
main
hoses
radiator
frame
(16) and
assembly.
30630
assembly
(18), then
(13)
about
disconnect
(17) from
radiator
100
mm
transmission
from
cooler
and lift off radiator
INSTALLATION
1.
Raise
radiator
OF RADIATOR
assembly
(13) and
set on main
frame
(18).
Radiator
&?Ikg
Connect
assembly:
transmission
183 kg
cooler
hoses
(16)
and
(17) to
radiator.
2.
Install
1)
radiator
Tighten
(13).
front
mounting
bolts
(14)
i,
13
14
Y
235C00205t
2)
Tighten
rear mounting
bolts
(15).
I
3.
Install
panel
(12) with
mounting
bolts
I
235COO205i
(11).
235CDO205E
30531
4.
Install
piping
and electric
1)
Install fan guard
2)
Connect
3)
Install
4)
hose (6) to sub tank (6A).

radiator
inlet
hose
aeration
hose (5) to engine.
Connect
heater
5.
Install
6.
Tighten
hood
tubes
Run
drain
the
valve
engine
the system.
Q
(3), outlet
hose
(8) and (9) to radiator
(4) and
(10).
(2).
and
ler (19) to the specified

*
wiring
(7).
add water
through
to
circulate
the
Coolant:
water
fil-
level.
58
water
through
level again.
235FO2215
30632
REMOVAL OF FUEL TANK

ASSEMBLY
Disconnect
the
lead from
the
negative
(-)
termi-
nal of the battery.

1. Remove
rear mount
For details,
ripper
assembly.
see REMOVAL
OF REAR MOUNT
valve
drain
RIPPER
ASSEMBLY.
2. Open
drain
(1) and
fuel
from
fuel
tank
(2).
3. Remove
fuel filler
pipe (3) from
fuel tank.
235FO2216
4. Remove
fuel
hoses
(4) and
(5) from
injection
pump
(6).
235FO2217
-I
5. Remove
wiring
6. Remove
cover
clips (9) and (9A).

(7) and disconnect
wiring
(8).
235F0221E
7. Set jack @ in position

Fuel tank:
8. Remove
mount
9. Loosen
nut
10.
under
it.
298 kg
bolt (IO), plate
(13),
and
then pull out shaft
(16).
Lower
fuel tank to support
jack 0 to lower
(II),
remove
and cushion
bolts
(14)
and
(12).
(15),
fuel tank.
30633
INSTALLATION OF FUEL
TANK ASSEMBLY
1.
2.
Raise fuel tank
(2) with
jack 0,
through
rear frame and fuel tank.
&I
Fuel tank:
then
pass shaft
(16)
298 kg
Secure shaft (16) with bolt (15).
235FO227C
3.
Fit nuts (13) up to head
of bolts (14), then
install to
frame.
4.
Adjust
left
position
and
right
of fuel tank by adjusting

bolts
(14)
are
amount
screwed
in
so
that
that
mount bolt (10) is installed straight in rear frame.

5.
When
position
bolts (14) with
of
fuel
tank
is determined,
nuts (13) in position
where
secure
bolts are
in contact with fuel tank.
6.
Install mount bolt (IO), plate (1 I), and cushion (12).
frame
ill
7.
Connect wiring (8) and install cover (7).
8.
Install wiring clips (9A) and (9).
l-1
235FO222'
235FO2221
30634
9. Connect
fuel hoses (4) and (5) to injection
pump
(6).
235FO2217
10. Install fuel filler

11. Close
drain
pipe (3) to fuel tank (2).
valve
(I),
then
add
fuel
through
fuel
fil-
ler.
12. Bleed air from
fuel system.
1)
Loosen
2)
Loosen
knob
up
down
and
air bleed
with fuel from
plug (17).
of feed
until
pump
no
air bleed
air bleed
more
(18).
and
bubbles
operate
come
it
out
plug (17).
3)
Tighten
plug (17).
4)
Push in knob of feed pump
(18) and tighten.
13. Install ripper.
14. Connect
cable to negative
(-)
OF RIPPER ASSEMBLY.
terminal
of battery.
30-35
0
DISASSEMBLY
1.
2.
OF PTO ASSEMBLY
Cover, tube
1)
Remove
2)
Disconnect
tube
(2).
tube
(3).
PTO assembly
Using
plate,
sling
PTO assembly
(4), remove
mount-
ing bolts, then lift off PTO assembly.

*
The
center
gravity
and .it will
fall
block
to. keep
when
lifting.
of the
over
it
to the
parallel
PTO assembly
front,
to
the
is high,
so use a lever
mounting
face
235COO2060
3.
O-ring,
gear
1)
Remove
O-ring
2)
Remove
gear (6) from
(5).
3)
Remove
bearing
transmission
(7) from
case.
gear.
P2350
4.
Tube
Remove
5.
tube
(8).
Gear assembly
I)
Screw
in forcing
bly (9).
30636
screw
and remove
gear assem-
D 205
2i
Remove
snap ring (IO),
then pull out gear from
cage.
3)
4)
Remove
bearing
Remove
snap
(1 1) from gear (12).

ring
(13),
then
pull out
bearing
(14) from cage (15).
P23505207
5)
6.
Remove
bearing
(16)
Cover, holder
1)
Using
forcing
screw
Pitch = 1.75 mm), remove

2)
7.
Remove
(Thread
dia.
12 mm,
cover (17).
holder (18).
Gear assembly
1)
Screw
in forcing
screw
and remove
gear assem-
bly (1 9).
2)
Remove
snap rings (20)
and (21),
gear from cage.

3)
Pull out bearing
4)
Remove
bearing
(22) from cage (23).

(24) from gear.
then pull out
P2350f208
5)
Remove
mounting
bolts then remove
shaft
from gear (26).

6)
8.
9.
Remove
bearing outer race (27) from case.
Lubrication tube
I)
Turn over PTO case.
2)
Remove
lubrication
tubes (28) and (29).
Idler gear assembly

1) Remove snap ring (30).
2)
Remove
shaft and bearing as one unit.
3)
Remove
bearing
(31) from shaft (32).
(25)
4)
5)
Remove spacer (33) and gear (34).

Remove spacer (35) and bearing inner race (36).
10. Shaft assembly

I) Remove snap ring (37).
2)
3)
4)
5)
Turn over case the put case on block.

Remove mounting bolts then remove holder (38).
Pull out bearing and shaft (39) as one unit.
Remove bearing (40) from case.
6)
7)
Remove bearing (41) and spacer (42) from shaft

Remove gear (43) and bearing.
11. Snap ring, bearing
1) Remove snap ring (44).

2)
Remove
case (47).
3020
bearing
outer
races
(45)
and (46)
from
ASSEMBLY
OF PTO ASSEMBLY
Preparatory work
l
Clean the lubrication
Apply
engine
oil circuit thoroughly.
oil to sliding portion of each part before
installing.
1.
Bearing, snap ring

1)
Press fit bearing
2)
Press
(46).
fit bearing
(451,
then
fix with
snap
ring
(44).
t
If bearing
(45)
goes
from the opposite
2.
on too far,
tap
it out
side.
Shaft assembly
I) Set bearing and gear (43) to case.
2) Press-fit bearing (41) to shaft then install spacer
(42).
z
kc
2
3)
Align
spline
of gear
shaft assembly
3.
4.
(43)
and shaft
(39).
4)
Fix with snap ring (37).
5)
Turn over case (47).
Bearing cover
I)
Press fit bearing
2)
Temporarily
(40).
install cover (I 7).
Holder
Fit dowel pin and install holder (38).
w
Mounting
bolt:
112.8 f 9.8 Nm
(11.5 + 1.0 kgm)
Turn over case (47).
then
install
5.
Idler gear assembly

I) Set bearing inner race (36) and spacer (35).
2) Set gear (34).
3)
6.
4)
Press fit bearing (31) to shaft and install spacer

(33).
Install shaft (32).
5)
Install snap ring (30).
Lubrication tube
Fit O-rings and install tubes (29) and (28).
30642
7.
Gear assembly
I)
Press fit bearing
2)
Install
shaft
(27) to case.
(25) to gear (26).
3)
Press fit bearing
4)
Press fit bearing
(24) to gear.
(22) to cage,
then
fix with
snap
ring (2 1).
5)
Press
with
6)
gear
Fit O-ring
*
8.
fit
(26)
to bearing
of cage,
then
fix
snap ring (20).
(48) and install
When
installing
ticularly
careful
bearing
properly.
gear assembly
gear
assembly
to mesh
(I 9).
(19).
be par-
the gear and fit the
Cover holder
1)
Screw
in
forcing
mm, Pitch 2)
Fit dowel
w
screw
(Thread
1.75 mm) and remove
pin and install

Mounting
bolt:
holder
cover
(18).
112.8 + 9.8 Nm
(11.5 + 1.0 kgm)
dia.
(17).
12
3)
Fit O-ring and install cover (17).
9. Gear assembly
1) Press fit bearing (I 6) to case.
2)
3)
41
5)
6)
Press fit bearing (I 4) to cage, then fix with snap

ring (I 3).
Press fit bearing (I 1) to gear (12).
Press fit gear (12) to bearing of cage (15). then
fix with snap ring (10).
Fit O-ring (49).
Install gear assembly (9) to case.

*
When installing gear assembly (9) be particularly careful to mesh the gear and fit the
bearing properly.
10. Tube
Install tube (8)
11. Gear, O-ring

1) Press fit bearing (7) to gear (6).
2) Install gear (6) to transmission case.
3) Fit O-ring (5).
12. PTO assembly

Sling PTO assembly
(4) and install
The
center
of
gravity
high,
and
it will
fall
lever
block
face when
to
keep
of
over
it.
the
PTO
to the
it parallel
assembly
front,
to
the
so use
is
a
mounting
lifting.
235COO2061
13. Tube
1)
Connect
2)
Install tube
tube
(3)
(2).
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
REMOVAL OF TRANSMISSION
ASSEMBLY
(AS INDIVIDUAL PART)
1.
2.
Remove ROPS cab.

Loosen
oil.
-
3.
5.
plug (I) of hydraulic
Hydraulic
Remove drain
drain oil.
-
4.
drain
OF ROPS CAB.
tank and drain
oil: 108 I?
plug (2) of transmission
Transmission
case : 25
Air tank assembly

Remove air tank assembly.
For details,
see REMOVAL
SEMBLY.
Hydraulic
tank assembly
Remove hydraulic
tank.
ASSEMBLY.
case and
OF AIR TANK
OF HYDRAULIC
AS-
TANK
DEG00006
Serial
6.
No.: 11001 - 12012,
12016 - 12018
Wiring
Serial No.: 11001 - 12012, 12016 - 12018
1) Disconnect
speed control
wiring
(3) from
transmission.
2) Disconnect
connector
(4).
I k
Serial
Serial No.: 12013 - 12015, 12019 and up
1) Disconnect
speed control
wiring
(3) from
transmission.
Connectors
to disconnect:
FW, RE, HI, LO,
Ist, 2nd, 3rd, 4th
2) Disconnect
connector
TM1 1 (3A).
.
wiring
3) Disconnect
connector
CN30 (4).
Speed sensor wiring
4) Disconnect
connector
TM10 (4A).
Transmission
oil temperature
sensor wiring
l
30-45-l
0
No.: 12013 - 12015,
DEG00007
12019 and up
DISASSEMBLY
7.
Remove
AND ASSEMBLY
engine
TRANSMISSION
stop motor (5).
-------_.--._-=-~
8.
Remove
between
bolt (7), then remove drive

final drive and transmission.
9.
Piping, control
1) Remove inching
mission.
control
shaft
($_
DEG00008
(6)
rod (8) from trans-
OEGOOOIO
2)
Remove hoses
draulic pump.
(9), (IO),
and (11) from
hy-
30-45-2
0
DISASSEMBLY
3)
Remove
block
4)
Remove
hoses
5)
Remove
air hose
6)
Remove
transmission
30-45-3
0
TRANSMISSION
AND ASSEMBLY
(12) from
frame.
(13) and (14).
(15).
oil filler
tube
(16).
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
assembly (171, then remove

10. Raise transmission
bolts (181, (19), and (20).
*
Check the number and location of shims (22).
\,\
DEGOOOl6
DEG00017
11. Remove transmission

assembly
frame when removing.
el
kg
Transmission
assembly
(17) from main
: 1200 kg
DEG00301
30-45-4
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
INSTALLATION OF
TRANSMISSION
ASSEMBLY
(AS INDIVIDUAL PART)
1.
Raise transmission
frame.
assembly
(17) and set main
Transmission
assembly : 1200 kg
&
kkgReplace O-ring (23) with a new part.
DEGO0019
2. Raise transmission
mount bolt.
1)
2)
assembly
(17)
and
install
Install bolt (18).

m
Bolt :
110.5 2 12.5 Nm Ill.25
t 1.25 kgm)
Insert shims (22) and install bracket (21).
*
Standard shim thickness: 4.1 mm
w
Bolts (19), (20) :
549 + 59 Nm I56 2 6 kgm)
I
3.
18
DEG00017
Install drive shaft (6) with bolts (7).
DFG00009
30-45-5
0
DISASSEMBLY
4.
AND ASSEMBLY
TRANSMISSION
Piping, control
I) Install air hose (15).
2)
Install hoses (13) and (14).
DEG00013
3)
Install block (12) to frame.
4)
Install hoses (91, (IO), and (II).
DDGOOOI
30-45-6
0
DISASSEMBLY
5)
Install
sion.
AND ASSEMBLY
inching
control
TRANSMISSION
rod (8) to transmis-
DEGOOOIO
6)
Install oil filler tube (16) to transmission.
erial No.: 11001 - 12012.
12016 - 12018
Serial No.: 11001 - 12012, 12016 - 12018

7) Connect connector (4).
8) Connect speed control wiring (3) to transmission.
.P
Serial No.: 12013 - 12015,
Serial No.: 12013 - 12015, 12019 and up
7) Connect connector CN30 (4).
*
Speed sensor wiring
8) Connect speed control wiring (3) to transmission.
Connectors to connect: FW, RE, HI, LO, Ist,
2nd, 3rd, 4th
9) Connect connector TM10 (4A).
.
Transmission oil temperature sensor wiring
IO) Connect connector TM1 1 (3A).
.
wiring
30-45-7
0
OEG00007
12019 and up
DISASSEMBLY
5.
install
6.

Install hydraulic
tank assembly.
TANK ASSEMBLY.
7.
8.
engine
TRANSMISSION
AND ASSEMBLY
stop
motor
(5).
Air tank assembly

Install air tank assembly.
For details,
see INSTALLATION
ASSEMBLY.
ROPS cab assembly
Install ROPS cab.
OF HYDRAULIC
OF AIR TANK
OF ROPS CAB.
30-45-8
0
DISASSEMBLY
ASSEMBLY
.
*
Preparatory
Sling
1.
work
transmission
@ (Height
OF TRANSMISSION
assembly
(I),
then
set it on block
= 470 mm).
PTO assembly
Sling
PTO assembly
then
remove
(2), remove
PTO
assembly
mounting
from
bolts
transmission
(3),
as-
sembly.
235CDO2061
2.
Transmission
1)
control
Remove
valve assembly
transmission
control
valve
19 mounting
bolts (4).
*
Do
not
remove
seat
%), or body service

*
The
length
of the mounting
so check the length
2)
Using
=
eyebolts
1.5 mm),
sembly
(5).
service
when
@ (Thread
sling
and
bolts
bolts (marked
(marked
A).
bolts
is different,
removing.
dia.
remove
10 mm,
control
valve
Pitch
as-
3.
Cage
Screw
Pitch
4.
in forcingscrew
= 1.75
(Thread
dia.
12 mm,
in place with
its trans-
cage (6).
Snap ring, seal ring

Remove
*
snap ring (7) and seal ring.
Set transmission
fer assembly
5.
mm), and remove
assembly
down.
Sleeve
Remove
*
sleeve
Using
(8).
eyebolt
(Thread
2.0 mm), remove
dia.
16 mm,
Pitch
sleeve.
6.
Transmission
1)
Using
= 1.75
2)
case
eyebolts
@ (Thread
dia.
mm), sling transmission
Remove
mounting
bolts,
then
12 mm,
Pitch
case.
remove
transmis-
sion case (9).
7.
Tie bolt
+
Using
tool
before
disassembling.
Remove
tie bolts
C check
(10).
operating
condition
of piston
8. Cage and reverse carrier assembly

Using
2.0
eyebolts
mm),
sling
(Thread
cage
(1 11, then remove
and
dia. =
16 mm, Pitch
reverse
carrier
assembly
it.
9. Spring
Remove
P2350
spring (12).
10. Spring, disc, plate

Remove
+
spring (13). disc (14). and plate (15) in order.
Springs
(13) are inserted
between
each plate.
11. Reverse ring gear

Remove
reverse ring gear (16).
12. No. 1 housing, reverse piston
Using eyebolts @ (Thread dia. = 16 mm, Pitch =

2.0 mm), sling No. 1 housing and reverse piston (1 7)
and remove
*
it.
Hold piston by hand to prevent
it from falling.
13. Snap ring, reverse ring gear

Remove
snap
ring
(18).
then
remove
reverse
ring
gear (19).
14. Spring
Remove
spring (20).

Remove
*
spring (21), disc (22).
Spring
18. Forward
Remove
(2 1) are inserted
ring gear
forward
plate (23).
between
ring gear (24).
each plate.
P23501244
I 242
17. Holder
Remove
holder (25).
18, I Forward carrier assembly

Using
2.0
remove
1)
eyebolts
mm),
sling
(Thread
forward
dia. =
carrier
16 mm, , Pitch
assembly
(26)
=
and
it.
Remove
snap ring (271, raise cage (281, then pull

(29).
out carrier assembly

2)
Remove
spacer (30).
P2350
19. Spring
Remove
20.
spring (31).
Spring, disc, plate

Remove
*
spring (32). disc (33), plate (34). in order.
Springs
(32) are inserted
between
each plate.
I249
P23501250
21. Guide pin

Remove guide pin (35).
22. 4th~speed ring gear
Remove 4th~speed ring gear (36).
23. Snap ring

Remove snap ring (37).
24. 3rd. 4th speed carrier assembly
Using bar and remove 3rd. 4th speed carrier assembly (381.
25. No. 2 housing, 3rd. 4th speed

Using eyebolts (Thread dia. =
mm), sling No. 2 housing and
(39) and pull them out.
piston
16 mm, Pitch = 2.0
3rd. 4th speed piston
it from falling.
26. Spring
Remove spring (40).
Remove spring (411, disc (421, plate (43) in order.
t
Springs (41) are inserted between each piston.
28. 3rd speed ring gear
Remove 3rd speed ring gear (44).
29. 3rd. 4th speed sun gear
I) Remove spacer (45) and 4th speed sun gear
(46).
2) Remove spacer (47) and 3rd speed sun gear
(48).
3) Remove spacer (49).
45
46
47
48
49
30650
30.
No. 3 housing,
Using
2.0
2nd speed
eyebolts
31.
Spring,
*
them.
it from falling.
spring (5 1).
disc, plate
spring (52),
Springs
disc (531, plate (54) in order.
(52) are inserted
1 st, 2nd speed carrier
Using eyebolts
2.0
mm),
2.0
eyebolts
mm),
each plate.
assembly
(Thread
dia. =
2nd speed
1 st speed
@
16 mm, Pitch
carrier
assembly
(55)
piston
(Thread
dia. =
sling No. 4 housing
(56) and remove

*
between
them.
No. 4 housing,
Using
sling lst,
and remove
34.
16 mm, Pitch
Spring
Remove
33.
dia. =
Remove
32.
piston
(Thread
sling No. 3 housing and 2nd speed piston
mm),
(50) and remove
16 mm, Pitch
and 1 st speed
them.
piston
it from falling.
36. Spring
Remove spring (57).
Remove wave spring (58), disc (591, plate (60) in
order.
t
Wave springs (58) are inserted between each
plate.
37. 1 st speed ring gear
Remove 1 st speed ring gear (61).
38. Cage assembly

2.0 mm), sling cage ksembly
(62) and remove it.
39. Spring
Remove spring (63).
Remove spring (641, disc (65). plate (66) in order.
t
Springs (64) are inserted between each plate.
41. Guide pin
Remove guide pin (67).
*
Guide pin (67) is different in length from guide
pin (35).
I2350
%252
PZ350
B262
Ring gear
42.
Remove
43.
ring gear (68).
No. 5 housing,
Using
2.0
low speed
eyebolts
mm),
Rotary
clutch
is a bearing
shaft,
so tap
Transfer
Pitch
piston
the
(70) and remove
assembled
transfer
it.
at the tip of the
case
with
a plastic
to remove.
assembly
Disassemble
transfer
For
see
details,
SEMBLY.
16 mm,
and low speed
assembly
There
hammer
45.
dia. =
them.
Sling rotary clutch assembly

t
piston
sling No. 5 housing
(69) and remove
44.
(Thread
assembly.
DISASSEMBLY
OF TRANSFER
AS-
ASSEMBLY
ASSEMBLY
*
Assemble
For
OF TRANSMISSION
transfer
details,
see
assembly.
ASSEMBLY
OF TRANSFER
ASSEM-
BLY.
Coat
sliding
portion
of each
part
with
engine
oil be-
fore installing.
Be careful
rection,
1.
Rotary
*
to install
the seal facing
and fit the spring

clutch
Assemble
securely
in the correct
di-
in the seat.
assembly
rotary
For details,
clutch
assembly.
see ASSEMBLY
OF ROTARY
CLUTCH
ASSEMBLY.
Sling
rotary
clutch
assembly
(70) and install
it.
s1
4
_-_,\\\\s,
2.
No. 5 housing,
1)
low speed
Fit seal rings
(71)
piston
and (721, then
install
piston
to
No. 5 housing.
*
Assemble
the housing
2)
Install
Using
with
the
seal
seal ring without
eyebolts
ring
3024
facing
(Thread
twisting.
dia. =
= 2.0 mm), sling No. 5 housing

piston
groove
side.
(69) and install them.
16 mm, Pitch
and low
speed
,,,:,,,,i\,,,~&\
zf
3. Ring gear
Install ring gear (68)
4. Guide
pin
Install guide pin (67).

t
Guide
pin (67)
is different
in length
from
guide
pin (35).
5. Spring,
disc, plate
Instal,l spring (641, disc (651, plate (66) in order.

*
Spring:
5 PCS, disc: 5pcs. plate: 4 PCS.
6. Spring
Install spring (63).
7. Cage assembly
Using
eyebolts
(Thread
dia. =
2.0 mm), sling cage assembly

*
Confirm
that
spring
(63)
16 mm, Pitch
(62) and install it.

is firmly
installed
groove of cage and piston.
8. 1 st speed
ring gear
Install 1 st speed ring gear (61).

9. Spring,
disc, plate
Install wave spring (58), disc (591, plate (60) in order.

*
Wave
spring:
3 PCS.
Disc:
3 PCS.
Plate:
2 pcs.
10. Spring
in
11. No. 4 housing, 1 st speed piston

I) Fit seal ring and install 1 st piston to No. 4
housing.
Sr When installing seal ring, refer to 2.-l 1.
2) Using eyebolts @ (Thread dia. = 16 mm, Pitch
= 2.0 mm), sling No. 4 housing and 1 st speed
piston (56) and install them.
+
Hold piston by hand to prevent it from falling.
+
Confirm that spring (57) is firmly installed in
groove of piston and housing.
12. 1 st, 2nd speed carrier assembly

Assemble 1 st, 2nd speed carrier assembly.
For details, see ASSEMBLY OF IST, 2ND SPEED
CARRIER ASSEMBLY.
2.0 mm), sling 1 st, 2nd carrier assembly (55) and install them.
*
Confirm that sun gear and ring gear are firmly installed to planetary carrier.

Install spring (52), disc (531, plate (54) in order.
Ir Spring: 2 PCS,disc: 2 PCS, plate: 1 pc.
14. Spring
Install spring (5 I).
15. No. 3 housing, 2nd speed piston
1) Fit seal ring and install 2nd speed piston to No. 3
housing.
*
When installing seal ring, refer to 2.-l 1.
2) Using eyebolts @ (Thread dia. = 16 mm, Pitch
= 2.0 mm), sling No. 3 housing and 2nd speed
(50) and install them.
+r Hold piston by hand to prevent it from falling.
+r Confirm that spring (5 1) is firmly installed in
16.3rd.
4th speed
sun gear
Install spacer (49). 3rd speed sun gear (48). spacer

(471, 4th speed sun gear (46) and spacer (45) in
order.
17. 3rd speed ring gear

Install 3rd speed ring gear (44).
44

Install spring (411, disc (421, plate (43) in order.
+I Spring: 3pcs. disc: 3pcs, plate: 2pcs.
lg.
Spring

p*l
5:
5
20. No. 2 housing, 3rd. 4th speed piston

1) Fit seal ring and install 3rd, 4th piston to No. 2
housing.
When installing seal ring, refer to 2-I).
*
2)
Using eyebolts (Thread dia. = 16 mm, Pitch =

2.0 mm), sling No. 2 housing and 3rd. 4th piston
(39) are install them.
Hold piston by hand to prevent it from falling.
t
*
Confirm that spring (40) is firmly installed in
P2350
I254
j ,,
,,
j
21. Sleeve
Install sleeve (73).
P2350E273
22. 3rd. 4th carrier assembly

*
Assemble 3rd, 4th carrier assembly.
For details, see ASSEMBLY OF PLANETARY
GEAR.
Fit seal ring (74). and install 3rd. 4th carrier assembly
(38).
+
Confirm that ring gear is firmly installed on planetary carrier.
23. Bearing, snap ring

Using
with
push tool
@ press
fit bearing
(76)
and fix
snap ring (37).
24. 4th speed ring gear

Install 4th speed ring gear (36).
25.
Guide pin
Install guide pin (35).
26.
Spring,
disc, plate
Install spring (32), disc (33),

*
plate (34) in order.
Spring: 3 PCS, disc: 3 PCS, plate: 2pcs.
27. Spring
Install spring (3 1).
28. Forward, reverse carrier assembly

*
Assemble forward, reverse carrier assembly.
For
details,
see
ASSEMBLY
OF
PLANETARY
GEAR.
1) Install spacer (30) to carrier assembly.

2)
3)
Install seal ring to cage (28).

Press fit carrier assembly
(29) to bearing
and fix it with snap ring (27).
3028
of cage
it
42. Seal ring

Install 2 seal rings (78).
43. Spacer, bearing, snapring
1) Install spacer (79).
2)
Press fit bearing
(80) and fix it with snap ring (7).
44. Cage
1) Install ball to cage and install caller (81).

2)
Press
fit bearing
(82)
and fix it with
snap
ring
dia. =
10
(83).
3)
Fit O-ring and install cage (6).
45. Control valve assembly

Fit O-ring
and using eyebolts
mm, Pitch
assembly
m
&
@ (Thread
1 .5 mm), sling and install control valve
(5).
Mounting
bolt:
49.0 + 4.9 Nm (5.0 & 0.5 kgm)
Mounting
bolt: Coat the bolt marked
@ with
gasket sealant (LG-5).
c3
@
@
235COO206:
46. PTO assembly

Fit O-ring,
assembly
30$2
sling PTO assembly

(1). then tighten
(2) install transmission
mounting
bolts (3).
235CDO2061
DISASSEMBLY OF CAGE AND REVERSE

CARRIER ASSEMBLY
1.
2.
3.
Forward
Remove
snap ring (1) and remove
2)
Remove
spacer
sun gear
Remove
sun gear (4).
Shaft
shaft
cage (6).
Cage assembly
1)
Remove
snap ring (7).
2)
Remove
cage assembly
ASSEMBLY
ASSEMBLY
*
(5).
Cage
Remove
5.
sun gear (2).
(3).
Reverse
Remove
4.
sun gear
1)
Coat
(8).
OF CAGE AND REVERSE CARRIER
sliding
portion
of each
part
with
engine
oil be-
fore installing.
1.
235FO2224
Cage assembly
1)
Install
2)
(9).
Press fit bearing
spacer
3)
Install
seal
(10)
2.
reverse
(12).
install
(8).
assembly
(8)
engaged
in
Cage
cage (6).
Shaft
Install shaft
4.
cage
assembly
snap ring (7).
Install seal ring (13) and install

3.
carrier
(11) to cage assembly
ring
and fix it with
to
Reverse
(5).
sun gear
InstaN sun gear (4).

*
5.
Confirm
that
planetary
gear.
Forward
sun
gear
is
firmly
sun gear
1)
Install
spacer
2)
Install
sun gear (2) and fix it with
(3).
snap ring (1).
OF 1 ST SPEED AND 2ND

DISASSEMBLY
SPEED CARRIER ASSEMBLY
1.
Low sun gear

1)
low sun gear
Remove
(2).
2)
2.
3.
Remove
spacer (3).
2nd speed carrier assembly

1)
Remove
2nd speed carrier assembly
2)
Remove
mounting
(4).
cage (5).
2nd speed ring gear and 1st speed carrier

assembly
1) Remove 2nd speed ring gear and 1 st speed carrier assembly
2)
4.
bolt and remove
Remove
(6) from shaft.
ring gear (8).
Shaft assembly
1)
2)
snap
Remove
ring
(IO)
from
remove
1 st speed sun gear (11).
Remove
spacer (12).
shaft
(9)
and
F23EC019A
P23EC
30664
I 56
P23EC
I 55
ASSEMBLY
OF 1 ST SPEED
CARRIER
*
Coat
sliding
before
1.
AND
2ND
SPEED
ASSEMBLY
Shaft
portion
of
each
part
with
engine
oil
installing.
assembly
I)
Install spacer (12) to shaft (9).
2)
Install
1st
speed
sun gear
(1 1) and fix it with
snap ring (10).

3)
2.
Install seal ring (13) to spacer (12).
2nd
speed
ring
gear
and
1st
speed
carrier
assembly
I)
Press fit bearing
(15) to 1 st speed caTrier assem-
F23ECO
IS
bly (14) and fix it with snap ring (I 6).

2)
Install
2nd
speed
ring gear
(8)
and fix
it with
snap ring (7).

3)
Install 2nd speed ring gear and 1 st carrier assembly (6) on shaft.
3.
2nd speed
1)
Press
carrier
assembly
fit bearing
(17)
to 2nd
speed
carrier
as-
sembly and fix it with snap ring (18).

2)
Install cage (5).

FZ&
s1
I.0
3)
i?
Mounting
Install
seal rings
(I 9).
Thread
(20).
tightener
Using
(LT-2)
press fit tool
(1) install 2nd speed carrier assembly
(4).
installed
Confirm
planetary
4.
bolt:
that ring gear is firmly
on
carrier.
Low sun gear

1)
Install spacer (3).
2)
Install low sun gear (2) and fix it with
snap ring
(1).
P23EC
P23EC
f 53
I 56
DISASSEMBLY
ASSEMBLY
1.
OF HIGH
ROTATING
CLUTCH
Shaft assembly
Remove
mounting
bolt and remove
shaft
assembly
(1).
2.
Spring, Disc, Plate

Remove
*
3.
4.
5.
wave spring (2), disc (31, plate (4) in order.
Spring: 4 PCS, Disc: 4 PCS, Plate: 3 PCS.
Sun gear
1)
Remove
snap ring (5).
2)
Remove
sun gear (6).
Cage assembly
I)
Put punch mark on cage (7) and carrier (8).
2)
Remove
bearing (9) together
with cage.
Planetary gear
Remove
planetary
details,
For
GEAR.
gear (10).
see
DISASSEMBLY
OF PLANETARY
ASSEMBLY
ASSEMBLY
Coat
OF HIGH
sliding
ROTATING
portion
of
each
CLUTCH
part
with
engine
oil
before installing.
1.
Planetary
gear
Install planetary
*
For
gear (IO).
details,
see
ASSEMBLY
OF
PLANETARY
GEAR.
2.
Cage assembly
1)
Press fit bearing
2)
Align the punch mark stamped
(9) to cage (7).
bly and install cage assembly

a>_
3.
Mounting
bolt:
during disassem-
(8).
Thread
tightener
(LT-2)
Sun gear
1) Install sun gear (6).

2)
Turn
carrier
assembly
over and fix it with
snap
ring (5).
4.
Spring,
Disc,
Plate
Install wave spring (2). disc (3) and plate (4) in order.
*
z
R
2
5.
Spring: 4 PCS, Disc: 4 PCS, Plate: 3 PCS.
Shaft
assembly
Install shat assembly
(1).
30667
DISASSEMBLY
1.
OF PLANETARY
(2) from planetary
Pull out shaft

and remove
ball (3). Then
gear (51, thrust washer

2.
carrier assembly
remove
thrust
washer
(1)
(41,
(6) in order.
Pull out bearing (7) from gear (5).
ASSEMBLY
*
GEAR
Coat
OF PLANETARY
sliding
portion
of
GEAR
each
part
23P322
with
engine
of
before installing.
1.
2.
Install bearing (7) in gear (5).

Inserting
washer
shaft
(2)
into
carrier
(61, gear (5). thrust
and
washer
install
thrust
(4) in order. Then
fix shaft with ball (3).

*
When
shaft
comes
out, lightly caulk ball groove
of carrier.
3.
After
assembly,
measure
gear (5) with feeler

internal clearance
*
Side clearance:
side clearance
gauge
within standard.
0.35
of planetary
(1) and confirm
to 0.80
mm
measured
rl
23P323
4
z
DISASSEMBLY
ASSEMBLY
OF TRANSFER
1.
Transmission assembly
Remove transmission assembly from transfer case.
For details, see DISASSEMBLY OF TRANSMISSION
ASSEMBLY.
i.
Speedometer output shaft, cover

1) Remove mounting bolts, then remove speedometer output shaft (1).
2) Using forcing screw 8, (Thread dia. = 12 mm,
Pitch = 1.75 mm), remove cover (2).
3.
Speedometer
1)
2)
4.
drive gear
bolts (3).
Remove speedometer drive gear (4).
Fjemove mounting
Input shaft cage, gear

1) Remove
mounting
bolts, then using forcing
screw @ (Thread dia. = 12 mm, Pitch = 1.75
mm), remove input shaft cage (5) and gear (6).
*
2)
Confirm
installation
direction
of gear (6).
Remove snap ring (7). then pull out bearing

from cage (8).
(9)
3029
5.
Cover, brake assembly

I) Remove mounting bolts, then remove cover (I 0).
2) Remove mounting bolts, then remove brake assembly (I I).
6.
Coupling assembly
I) Remove mounting
(I 3).
2)
3)
7.
bolts (I 2) then remove holder
Remove coupling assembly (I 4).

Remove mounting bolts (I 5), then remove plate
(I 7) from coupling (I 6).
Output shaft assembly

I) Remove mounting bolts, then using eyebolts @
(Thread dia. = 12 mm, Pitch = 1.75 mm), sling
output shaft assembly
2)
Remove
30670
mounting
(I 8) and remove
it.
bolts (I 9). then remove
cage.
3)
4)
5)
6)
Remove oil seal (21) from cage (20).

Put tool (inside diameter: 90 mm; height: 150
mm) in contaot with bearing (221, push out
shaft, and remove bearing (23). spacer (24).
gear (251, and spacer (26) from shaft (27).
Remove cover (28). bearing (22) from cage (29).
Remove bearing (3 I) from case.
39
21
22
29
40
28
24
26
25
23
31
8.
Cover, idler gear assembly

1) Remove mounting bolts, then using forcing
screw @ (Thread dia. = 12 mm, Pitch = 1.75
mm), remove cage.
2) Remove bearing (331, O-ring (34) from cage
(32).
3)
4)
5)
Remove gear assembly (35) from case (30).

Remove 2 bearings (36) from gear assembly.
Remove bearing outer race from case (30).
P23508300
9.
Strainer
Remove connector (38) and strainer.
DISASSEMBLY
ASSEMBLY
OF TRANSMISSION
CONTROL VALVE
UPPER VALVE
235FO2225
LOWER VALVE
235FO2226
30-&76
UPPER VALVE
1.
Remove
2.
Disassembly
covers
Remove
Check
shim
(4), then
the
remove
2.
guide
(5), shim
(II),
thickness
of
the
valve.
3.
guide
(IO), then
(12),
valve
(13),
number
and
remove
spring
thickness
1) Remove
valve
and spring
2) Remove
5.
g
z
z
6.
valve
spring
(20), then
(22), valve
(17),
shim
Remove
stopper
2)
Remove
valve
remove
number
and
valve
thickness
(54). and
stopper
(55),
then
(56).
of valve for F, R clutch

(57), then
remove
collar
(58)
(60), then
remove
collar
(61)
(59).
Remove
spring
(62).
Disassembly
(26), then
of pilot reducing
pressure
Check
the
shims,
and keep in a safe place.
remove
spring
(65)
valve
and valve
of the
number
(67),
and
and
valve
valve
shim (64).
thickness
shim
(68),
of the
(66),
then
spring
(69),
(70).
Check
the
shims,
number
and
thickness
of the
valve
5.
remove
Remove
spacer
(71).
plug (27).
of inching valve
cover
(30), then remove
3)
Remove
cover
(32).
4)
Remove
spool
(33).
5)
Remove
stopper
Remove
then
spring
Remove
2) Remove
(21),
(25).
1)
2) Remove
spring
(52),
1)
(18),
(23), and shim (24).
of quick return
1)
6)
locknut
(28) and yoke
(34), spring
(37), spring
valve
(42),
(45), and valve

7.
(16),
stopper
stopper
(53).
spring
valve
clutch
and
Disassembly
(19).
shims,
Remove
(51)
1) Remove valve (63), then remove
the
Disassembly
Remove
and valve
the
valve.
Check
Disassembly
valve
and valve
4.
of modulation
spring
Remove
Disassembly
of valve for L, H, 4,3,2,1
(14),
of
(49).
spring
2)
the
body
Disassembly
remove
(9) and
(50) from
1)
2)
(15).
Check
cover
remove
and
of priority
valve
shims,
4.
Remove
(8).
number
spring
and valve
*
1.
(1).
Disassembly
Remove
body
of cooler bypass valve
(7), and piston
shims,
3.
(2) and (3) from
spring
(6), valve
*
LOWER VAVE
seal (31).
(35), shim
(36),
(38), and shim (39).
(40), then
valve
(29).
(43),
remove
sleeve
valve
(44),
(41),
spring
(46).
Spacer
Remove
plug (47), then
remove
spacer
(48).
30677
ASSEMBLY
OF TRANSMISSION
CONTROL VALVE ASSEMBLY
UPPER VALVE
LOWER VALVE
235FO2225
235FO2226
REMOVAL OF HYDROSHIFT
TRANSMISSION
PUMP ASSEMBLY
A
1.
Lower
the
ground
and stop the engine.
Remove
Remove
see REMOVAL
inlet
transmission
3.
Remove
pump
equipment
the
and
OF AIR TANK ASSEMBLY.
outlet
tube
(1) and
hose
(2) from
pump.
mounting
bolts
Hydroshift
(3) and
transmission
INSTALLATION
TRANSMISSION
Install
transmission
remove
transmission
mounting
Install
and outlet
inlet
mission
pump
assembly:
12 kg
OF HYDROSHIFT
PUMP ASSEMBLY
pump
and tighten
For
to
(4).
6?lkg
Install
completely
air tank assembly.
For details,
2.
work
bolts
tube
assembly
(4) to
PTO
(5)
(3).
(1) and
hose
(2) to trans-
pump.
air tank assembly.
details,
see
INSTALLATION
OF AIR
TANK
AS-
the
sys-
SEMBLY.
Run the
engine
to circulate
tem.
Then check the oil level again.
30680
the
oil through
REMOVAL OF TANDEM AND

FINAL DRIVE ASSEMBLY
1.
Cover
Remove
2.
cover
Draining
Loosen
U
and (1 B) from
final drive.
oil of final drive case

drain
(IA)
plug (1) and drain final drive
Final drive
case:
case oil.
57 II
235FO2227
3.
Piping of final drive case

Remove
4.
tubes
(2), (2A) and hoses
bolts
(4),
(3), (3A).
Hanger
Loosen
disconnect
hanger
(5)
and
main
frame.
235FO2228
5.
Brake hose
Disconnect
6.
brake hoses (6) and (7) from
joint
(8).
Drive shaft
Loosen
tween
bolts
(IO),
transmission
then
remove
drive
shaft
(9) be-
and final drive.
30A8 1
7.
Cap
Support
final
drive
(11) with jack 0,

*
8.
Distinguish
Tandem,
between
out tandem
After
main
frame
cap
L.H. and R.H. caps.
rear end, and turning
and final drive assembly

pulling
out tandem
wheel,
pull
(12) to rear.
and final
bly, support body with block.
30$2
mounting
final drive assembly
Lift up main frame

+
and
and remove.
drive
assem-
INSTALLATION OF TANDEM
AND FINAL DRIVE ASSEMBLY
1.
Tandem
1)
Lift up main
frame
set
and
tandem
rear end, turn
final
drive
the wheel,
assembly
(12)
and
under
the chassis.
2)
Slowly
lower
the
and final drive
chassis
assembly
and
while
connect
moving
tandem
them.
\\\
2.
shims
ing cap (II),

Adjusting
of final
drive
then support
and
main
with jack 0,
frame
mount-
and install.
shims
1) Tighten
bolt (B).
Tighten
bolt (A) and measure
clearance.
3)
Loosen
bolt
shim
= clearance
g
z
z
235FO2231
Cap
Adjust
(A) and
above)
insert
(13)
(thickness
in (A) end.
4)
Loosen
bolt (B).
5)
Tighten
bolt (A).
3)
Tighten
bolt (8).
Mounting
bolt:
Thread
Mounting
bolt:
2745.9 + 294.2 Nm
tightener
(LT-2)
235COO2065
(280 + 30 kgm)
6
3.
13
235FO223;
Drive shaft
Using
dial
runout
of
gauge,
check
coupling
coupling
face
missible
value,
that
face
at
final
then
radial
at
drive
install
runout
transmission
end
drive
are
shaft
end
(9) with
bolts
of the
method
of measuring
values
for
radial
see
INSTALLATION
and
per-
permissible
runout,
face
within
(IO).
*
For details
the
and
runout
OF ENGINE
and
the
and face
ASSEM-
BLY.
*
If they
are
not within
just the engine

w
mount
Mounting
bolt:
the
permissible
value,
ad-
shims.
110.3 + 12.3 Nm
(11.25 i
1.25 kgm)
30683
Hanger
Install
hanger
(5) on main frame
by bolts (4).
Hanger
mounting
bolt:
Thread
Hanger
mounting
bolt:
926.7 -
tightener
(LT-2)
103.0 Nm
(94.5 k 10.5 kgm)

Final drive case piping
Install
tubes
(2), (2A),
hoses
(3), (3A) and
drain
plug
(1).
235FO2227
6.
Install cover
(IA)
and (1 B) to final drive.
3A
235FO2228
7.
Brake hose
Connect
brake hoses (6) and (7) to joint
Refilling
Tighten
final drive case with oil

final
oil through
Q
(8).
drive
oil filler
Final drive
Run engine
case
drain
case:
then
add
level.
63 Q
to let oil circulate
30684
plug,
(13) to the specified
in hydraulic
system.
engine
DISASSEMBLY
ASSEMBLY
Special
1.
OF FINAL DRIVE
tool
I
I
Part number
792-571-l
1 Chain puller-
600
Part name
Tandem
1)
details,
For
see
DISMOUNTING
I Oe
TANDEM
DRIVE
AND FINAL DRIVE ASSY.

2)
Sling
tandem
and
remove
wheel
& kg
Tandem
final
and
out wheel):
3)
drive
assembly
(1) and
(2).
Set
tandem
and
0,
remove
drain
final
drive
assembly
(with-
4290 kg
final
drive
plug
(3)
assembly
and
on
drain
block
tandem
case oil.
.(.
4)
Tandem
Remove
drain
case (each):
plug
(4) and
Approx.
drain
120 9.
final
drive
case
oil.
u
*
Set
Final drive
block
R.H. tandem
2.
with
covers
three
Approx.
places
(5)
63 Q
under
case and final drive.
Cover
Remove
case:
the
L.H.
and
Chain
I) Turn the pinion and align
chain to access position.
connection
2)
chain,
Using tool
squeeze
the
pin (6) and pull out connection
3)
lock
Remove chain (8).
& kg
Tandem case assembly
Drive shaft
Remove bolts
from coupling.
3026
remove
pin (7).
Tandem case assembly

1) Sling tandem case assembly (9).
2) Remove
mounting
bolts (IO),
tandem case assembly.
5.
part of
(111, then
remove
then
(each):
drive
remove
1242 kg
shaft
(I 2)
6.
Coupling
Pull out coupling
7.
(13) from pinion shaft.
Tube
Remove
tube (I 4) together
with O-ring.
235FO2233
8.
Strainer
Remove
9.
Cover,
spring (15) and strainer
(I 6) from pipe.
pipe
1)
Remove
pipe (17) together
2)
Remove
cover (18).
with O-ring.
10. Tube
Remove
tubes
(19)
and
(20)
then
remove
flanges
(21) and (22).
11. Side case assembly

Remove
ers (24),
(25) from
kg
ET?!
side case mounting

then
center
sling
bolts
and remove
(23) and 24 washside case
assembly
case.
Side case assembly
(each):
655
kg
P2350
I325
I2350
1326
12. Plate
Remove
bolt (26) then remove
plate
(27).
P2350
I327
ti
0
13. Carrier assembly

Sling and remove carrier assembly (28).
63
kg
Carrier assembly: 1 10 kg
14. Gear, carrier, pin

Remove bolts (29), lock plate (301, plate (31) and Pin
(32). then remove gear (33).
15. Holder, shim

Remove holder (34) and shim (35).
16. Sprocket
Remove sprocket (36) from shaft.
17. Bearing
Remove
bearing
18. Rear axle
(37) from shaft.
shaft
assembly
Pull out rear axle shaft assembly

lg.
Plate
Remove
20.
21.
(38) to lower side.
bolts (39). washer
Washer,
O-ring,
Remove
washer
(40) and plate (41).
shim
(42). O-ring
Flange
Sling and remove
Flange:
Remove
O-ring
flange
74 kg
(46)
(45).
(43) and shim (44).
22. Side case

1) Pull out 2 bushings (47).
2)
Remove
washer
(49) from side case (48).
23. Shaft, bearing
Pull out bearing (5 1) from shaft (50).
24. Ring gear

Remove
ring gear (52) from center case.
25. Sun gear

Remove
snap ring (53)
from axle shaft,
collar (54) and sun gear (55).
then remove
26. Shaft
Remove axle shaft (56) from center case.
27. Bevel pinion assembly

1) Remove cover (57).
2)
Remove bevel pinion assembly

with shim (59).
& kg
together
Bevel pinion assembly: 74 kg
Check the number and positions of the shims

which were removed.
28. Bevel gear assembly

1) Sling bevel gear assembly (60).
30692
(58)
2)
Remove
bolts
(65), then
remove
cages
(62) and
(63).
3)
Remove
t
shim (64).
Check
shims
the
number
on the
left
and
and
thickness
right,
and
of
keep
the
in a
safe place.
4)
Raise
bevel
center
case (61).
& kg
5)
Remove
gear
assembly,
Bevel gear assembly:

bolt (67), then remove
and
remove
from
188 kg
gear (66).
30693
OF FINAL DRIVE
ASSEMBLY
ASSEMBLY
Special
tool
Part number
1.
792-571-l
Center
1)
Part name
600
Chain puller
gear
(66) to center
Set left and
right
then
temporarily
(with
bearing
Insert
shims
Types
t -
(61) with
dowel
(64) on center
cages
races already
(64) on the
during
(61),
and
(63)
press fitted).
left
as
case
(62)
and
those
right
which
of the
were
disassembly.
of shims
0.1 mm
t = 0.2 mm
t = 0.5 mm
Bevel gear assembly

Sling
bevel
install
bearing
gear
assembly
outer
(60) and install
case, then
race of cage.
Bevel gear assembly:
A kg
3.
shims
thickness
removed
case
bolts (67).
assemble
outer
same
2.
case assembly
Position
pin, then install with

2)
Oty
188 kg
Bevel pinion assembly

1)
Fix
O-ring
assembly
*
insert
Backlash
i)
shim
(59),
install
(58) and it is engaged

Insert
adjusting
during
shims
as those
(59)
which
of the
were
Standard
iii)
Type of shims
shim thickness:
same
removed
disassembly.
ii)
pinion
gear.
shims
adjusting
thickness
bevel
in bevel
2.0 mm
t = 0.1 mm, t y 0.2 mm, t = 0.5 mm
2)
Measuring
with
Put a fuse
wire
the
of
teeth
Rotate
the
thickness
*
3)
fuse wire
@ (approx.
the
bevel
gear
bevel
gear
and
of the wire with
Put the fuse
wire
41.5
mm)
and
then
pinion.
measure
a micrometer
in the
between
bevel
center
the
0.
(approx.
20
mm from small end) and measure at least

three points around the gears.
Standard value for backlash: 0.25 to 0.33
mm
Measuring
preload
@ and bolt @ (16 mm x 2 mm 120 mm) to bevel pinion assembly, then measure
starting torque with torque wrench 0.
Install
locknut
Adjust
so that the starting
torque
pinion
is 0.68
(0.07
greater
alone
than
9.8 -
When
the
1.0 Nm
torque
for
12.8 Nm (1 .O -
doing
at the outside
this,
measure
circumference
the
at the bevel
-
0.10
kgm)
bevel
pinion
1.3 kgm).
the starting
torque
of the bevel
gear
alone.
Starting
force
(bevel
gear alone):
9.8 -
12.8 N (1.0 -
1.3 kg)
4.
Testing
Adjust
tooth
and adjusting
preload
contact
Adjust
to taper
of bevel
bevel
of 9.8 to
roller
pinion
12.8
bearing,
gear and bevel

assembly
Nm
(1.0 to
backlash
and
pinion.
for
starting
1.3 kgm)
force
as a single
assembly.
Install
bevel
same shims
Perform
tooth
pinion
before
adjustment
contact
Measure
while
assembly
as those
of
on
starting
preload,
torque
adjusting
change
the
cages
with
the
backlash
and
in parallel.
of bevel
bevel gear is in mesh with
When
case
removal.
the
preload
amount
at the
left
of
and
gear
bevel
of
shims
right
assembly
pinion.
the
bearing,
inserted
sides
in
of the
the
center
a=20to33mm
b = 13to26mm
case.
end side
Small
23F032
1)
Adjust
tooth
contact
Coat
the
tooth
with
red
lead
forward
and
face
of the
(minimum).
backward
bevel
Rotate
and
pinion
the
inspect
lightly
bevel
the
gear
pattern
left on the teeth.

*
The
center
should
small
of
be
end
the
center
are
adjusted
the
located
of the
If the
correct
adjust
result
tooth
of the
contact
26
gear.
tooth
this
tact will be correct

t
bevel
of the
to
tooth
13
again as follows.
If the
the
the
be in
gears
tooth
con-
load is applied.
inspection
contact
pattern
from
It should
height.
pattern,
when
mm
is not
shows
being
that
the
obtained,
i)
If bevel
bevel
pinion
Contact
is at the
center
end
of
gear
and
end of the concave
tooth
face.
Procedure
the
B by
the
has
contact
pattern
If bevel
big
shims
the
bevel
gear.
at
both
cages
bevel
gear
amount
at
pinion
the
in
Adjust
of
the
in direc-
that
the
bevel
Check
the
tooth
and backlash
again.
is too
to center
line
of the
concave
of the
Procedure
Increase
bevel
close
of
tooth
the
end
gear
and the big end
face.
thickness
pinion
the
small
bevel
for adjustment
direction
tion
convex
at the
nearer.
is at the
face
of the convex
bevel
of
gear.
Contact
just
the
the
same
moved
pinion
the
move
to the
to move
pinion
tooth
to
thickness
gear
tion
of
mount
A, nearer
shim
bevel
small
thickness
pinion
direction
bevel
line
for adjustment
the
bevel
from
bevel
face
Reduce
ii)
far
of the
tooth
*
is too
gear.
A,
away
shim
gear
B by
of
mount
to
from
thickness
to move
the
bevel
pinion
tooth
contact
pattern
the
shims
the
bevel
amount
moved
at the
pinion
bevel
at both
the
same
has
the
move
gear.
cages
gear
equal
away.
and backlash
in
Ad-
of the
in directhat
the
Check
the
again.
23FO50
30697
6.
Shaft
Install axle shaft (56) to center case.
6.
Sungear
Install sun gear (55)
and collar (54) to axle shaft, and
fix them with snap ring (53).
7.
Ring-gear
Install ring-gear
8.
Shaft,
(52) to center case.
bearing
Press fit bearing (51) to shaft (50).

*
When
from
doing this, position
bearing is distance
30698
it so that the distance
the end face of the shaft

A (1 15 mm).
to the tip of the
9. Side case
i) Assemble washer (49) to side case (48) (with
bearing and oil seal) so that end of washer is as
shown in diagram on right.
#TIJ=
ii)
Washer (contact surface) :

Anti-friction compound (LM-P)
Assemble
compared
Assemble
at the top
case.
&
bushing (47) so that slit is at bottom

to UP mark on side case.
the second bushing so that the slit is
compared to the UP mark on the side
Bushing: Anti-friction compound (LM-P)
10. Flange
Fit O-ring to side case, then sling and install flange
(45).
ks
C?J
Flange: 74 kg
O-ring: Grease (G2-LI)
11. Washer, O-ring, shim

i) Assemble washer (42) so that end of washer is
as shown in diagram on right.
ii) Assemble O-ring (43).
ECC&
Washer (contact surface):

Anti-friction compound (LM-P)
iii) Assemble shim (44) so that it is the same height
as washer (42).
*
Standard shim thickness: 1 .O mm
(t = 0.1 mm, 0.2 mm, 0.5 mm) .
12. Plate
Install
(41)
plate
and tighen
bolts
(39)
with
washer
(40).
Bolt:
549.2 * 58.8 Nm (56 YC6 kgm)
13. Axle shaft assembly

Install axle shaft assembly
(38).
14. Bearing
Install bearing
(37) to shaft.
15. Sprocket
(36) to shaft.
Install sprocket
*
Assemble
the sprockets
so that the long ribs are
alinged.
16. Adjusting
i)
Install
(34).
30-A00
preload
shim
of axle
(35)
and
shaft
bearing
temporarily
install
holder
ii)
Install
3 gears
(33) to carrier
with
pin
(32), plate
(31) lock plate (30), and bolts (29).
iii)
Sling and install

Carrier
rE?kg
iv)
Install
plate
w
*
carrier
assembly:
P2350
B328
P2350
I327
bolts (26).
926.7 + 103.0 Nm (94.5 k 10.5 kgm)
Tighten
bolt
plate
(27)
shim
(35)
to 9.8 -
(26) and
and
bring
shaft
the
(38)
installed
the
torque
starting
(t =
faces
contact.
in
Step
of the
of
Add
16)
bearing
1.3 kgm).
shim thickness:
of shims:
end
in
(temporarily
12.8 Nm (1.0 -
Standard
Type
(28).
110 kg
(27) and tighten
Bolt:
and adjust
*
assembly
2.0 mm
0.1 mm,
t =
0.2 mm,
= 0.5 mm)
Rotate
and
the
right
starting
shaft
to
at least
settle
torque
again.
washer
(67) with
Bolt:
the
three
bearing,
Install
times
to the
left
check
the
(34) and
lock
then
holder
bolt (68).
277.0 + 31.9 Nm (28.25 + 3.25 kgm)
17 . Side case assembly

and
Sling
install
case and tighten
side case
&
Side case assembly
KI&
Bolt (26) and axle shaft contact

Antifriction
Side case mounting
bolt:
(24).
kg
655
(each):
to center
(25)
assembly
24 bolts (23) with washer
surface:
compound
(LM-P)
549.2 f 58.8 Nm
(56 k 6 kgm)
18. Tube
Install flanges
(22)
and (2 I) then connect
tubes
(20)
and (1 9).
19. Cover,
pipe
i)
Install cover (I 8).
ii)
Fit O-ring
lower side.
and
install
pipe
(17)
suction
port
at
20. Strainer
Install strainer (16) and spring (15) to pipe.
21. Tube
Fit O-ring and install tube (14).
235FO2233
22. Coupling
Install coupling (13) to pinion shaft.
23. Drive shaft

Install drive shaft (12) to coupling and tighten bolts
(1 1).
26. Cover
Attach gasket on covers (5) (Front and rear: 6
PCS).
&
Mounting bolt (tandem case side) :

Liquid gasket (LG-1)
dII&
Gasket side: Liquid gasket (LG-1)
27. Tandem and final drive assembly

I)
Lift tandem and final drive assembly (1) and install wheel (2).
2) Tighten tandem case drain plug and refill engine
oil through filler port to the specified level.
Q
3)
Tandem case (each): Approx. 120 Q
Tighten final drive case drain plug and refill gear

oil through filler port to the specified level.
lb
Final drive case: Approx. 63 Q
DISASSEMBLY
ASSEMBLY
1.
Remove
bolts
gear (3) from
(I),
OF BEVEL GEAR
lock
differential
plates
(2) then
remove
bevel
case A (4).
2.
Remove
bolts,
3.
Remove
bearing
(6) and seal ring (7) from
cage (5).
4.
Remove
piston
(8) from
remove
ring (9) from
5.
Remove
lock plates them
piston
cage
remove
(5) then
cage (5).
seal
(8).
seal ring (10) and washer
(1
1) from cage (5).
6.
Remove
*
mating
Mating
plates (121, discs (13) in order.
plate:
7 PCS, disc:
6 PCS.
7.
Remove
plate (I 4).
8.
Remove
gear (I 5) from differential
9.
Remove
differential
case A (4).
case
(16)
case.
from
differential
10. Remove
cross joint
11. Remove
pinion
and 19D) from

12. Remove
nion
nut
(19) and
assembly
(18, 18A, 19, 19A, 19B, 19C,
assembly
cross joint
(18A)
from
bearing
(17).
(17).
sleeve
assembly
(18), then
(19A,
remove
19B.
pi-
19C, and
19D).
13. Remove
ferential
30208
gear
(20) and
case A (4).
thrust
washer
(21) from
dif-
ASSEMBLY
ASSEMBLY
1.
2.
Install
OF BEVEL GEAR
thrust
washer
case A (with
bearing)
Press fit bearings

to pinion
(20) to differential
(19A), (19B) and spacers
(19C), (19D)
(19).
2A. Insert sleeve
(18) and tighten
Nut:
This bearing
and
(21) and gear

(4).
490.3 -
small
nut (18A).
608.0 Nm (50 -
62 kgm)
is a set, so the combination

bearings
and
of large
2 spacers
must
not
all have
the same
be
changed.
*
The bearings
and spacers
sym-
bols on the end face.
4
s1
After
tightening
the nut to the specified
tate the bearing

rotates
at least 5 times,
ro-
that
smoothly.
3.
Install
cross joint
assembly
4.
Install
differential
case B (16) to differential
5.
Install
gear
(17).
torque,
and check
(17).
(15) bite on pinion
case A (4).
of cross joint
assembly
it
6.
Install plate (14).

*
Assemble
are 15
mating plate (121, disc (13) in order.
the discs so that lubricating

-
22
apart.
disc so that it is rotated
holes
To do this, insert the 2nd

three teeth from the 1 st
disc.
*
Plate:
7 PCS, disc:
6 PCS.
(1 1) to cage (5).
7.
Install seal ring (I 0) and washer
8.
Install seal ring (9) to piston (8) and install to cage (5).
30210
9. Install
them
10. Stop
bearing
(6), seal ring
(7)
to cage (5) and install
by bolts and lock plate.
bevel
gear
(3) with
A (4),. then install with
dowel
pin of differential
case
lock plate (2) and bolt (1).
30211
DISASSEMBLY
ASSEMBLY
1.
Set
bevel
pinion
OF BEVEL PINION
assembly
(I)
in vice
and
remove
nuts (21, (3) and lock plate (4).
2.
Use press fit tool @

in press.
separate
*
Press
(I.D. 4200
pinion
(6).
mm) and set cage (5)
pull it out from
cage
to
pinion and cage.
It is possible
to remove
bearing
(7) and pull out
pinion at the same time.
3.
Remove
bearing
PCS.) and O-ring
4.
outer races
Use a bearing separator,
30212
(8) (upper and lower:
(9) from cage (5).
pull out bearing
(IO).
ASSEMBLY
ASSEMBLY
1.
OF BEVEL PINION
Use press fit tool to press fit bearing
(10).
P2350t366
2.
Using
press
and lower:
3.
4.
Fit O-ring
Pass
fit tool,
press
fit
outer
races
(8) (upper
2 PCS.) in cage (5).

(9) to cage (5) and install
bearing
(7) through
pinion
pinion
(6).
(6) and
press
fit
to
cage (5).
6
5.
Bearing
Set the
pinion
roller section:
Fill with
in a vice
install
and
grease
nuts
G2-LI.
(3), (2) and
lock plate (4).

6.
Starting
1)
torque
Tighten
*
adjustment
nuts (2) and measure
Starting
torque:
starting
torque.
49.0 to 58.8 Nm (5 to 6 kgm)
2) Turn the shaft at least 3 times left and right,

then
loosen
nut
(2) so that
it can start
to rotate
at 4.9 to 7.9 Nm (0.5 to 0.8 kgm)

*
3)
Do not fully
Tighten
*
second
Tightening
loosen
the nut.
nut (3).
torque
of second
nut:
392.3 & 98.1 Nm (40 k IO kgm)

*
Starting
torque:
9.8 to 12.8 Nm (1.0 to 1.3 kgm)
Measure
pinion
the
shaft
rotating
3 times
force
and
again
after
fits well. Then bend lock plate
the
after
bearing
rotating
roller
(4) securely.
P2350t363
Pirs50
I 367
REMOVAL OF FRONT
ASSEMBLY
1.
Front wheel
AXLE
assembly
1)
Loosen
wheel
2)
Raise front
support
nut (1) a little.
wheel
using
the lower
the
blade
part of frame
as a jack
center
and
firmly
with
wheel
nuts
a block.
3)
Temporarily
sling
(1) and remove
Front wheel
kg
r6?l
2.
Front axle
1)
Sling
wheel
wheel
and
remove
assembly
assembly:
(2).
530 kg
assembly
front
axle
assembly
(3)
and
put
on the
block 0.
2)
Remove
leaning
cylinder
and
steering
cylinder
and remove
leaning
hoses (41, (5). (6) and (7).
3)
Remove
bolt
rod (8) from

stopper
(91, pin (IO),

bracket
bolt (12).
(11)
then
remove
leaning
3.
Center pin
1) Remove stopper bolt (13).
2)
Remove
assembly
&
center pin (141, then remove

(3) from main frame.
Front axle assembly:
1080
kg
front
axle
INSTALLATION
ASSEMBLY
1.
AXLE
Sling front axle assembly (3). matching center hole

@ and main frame hole 0.
Always align the holes with left mount @ of the leaning rod and leaning stopper @ removed.
-- kg
&?I
2.
OF FRONT
Front axle assembly: 1080 kg
Fit center pin (14).
Tighten stopper bolt (13).
3.
Fix stopper bolt (12) to leaning rod (8).

Install leaning rod L.H. side to bracket (1 I) by pin (10)
and bolt (9).
&
Bolt (9): Thread tightener (LT-2)
Bolt (9): 147.1 - 308.9 Nm (15 - 31.5 kgm)
4.
hoses
(6), (7),
der and steering
Connect
cylinder.
(4) and
(5) to
leaning
cylin-
36
5.
Front wheel
1)
install
2)
assembly
Temporarily
sling
to
hub
front
shaft
tighten
wheel
nut (1).
Raise
front
wheels
remove
the
wheel
assembly
assembly
and
using
block,
and
blade
lower
(2), then
temporarily
as
body
a
to
jack,
the
ground.
3)
Tighten
wheel
el
Front wheel
kg
nut (1).
assembly:
&
Wheel
nut: Anti-friction
Wheel
nut:
530 kg
compound
(LM-P)
2206.5 k 245.2 Nm (225 f 25 kgm)
P2350
E369
OF FRONT AXLE
DISASSEMBLY
ASSEMBLY
*
Drain the oil from

I
1.
2)
cylinder
bolt
steering
cylinder
(4).
Loosen
(3) bottom
(5) and
locknut
end
remove
remove
(2),
pin
from
steering
front
axle
cylinder
(6).
15 kg
cylinder:
Tie rod assembly

1)
remove
(7) and
Loosen
locknut
(8) from
hub shaft assembly.
Leaning
1)
rod, leaning
Loosen
bolts
tie rod
assembly
54 kg
Tie rod assembly:
3.
out
hub shaft assembly
Steering
& ks
pull
and
(I)
Loosen
head end from
2.
1.8 11
Front axle housing:
Steering
1)
inside the housing.
cylinder
(9), (10) and
pull
(13)
and
out
washer
(II),
pin (12).
rod
leaning
Remove
(14) head end from

Leaning
30218
yoke
rod:
(15).
50 kg
leaning
cylinder
2)
Loosen
bolt
remove
leaning
(16)
and
pull
cylinder
out
bottom
(17).
then
end from
pin
front
axle.
Leaning cylinder:
& kg
4.
5.
6.
26 kg
Kingpin
Loosen
bolt
remove
hub shaft assembly.
(18)
and
pull out
&
Hub shaft assembly:
king
154
pin (191,
then
kg
Bracket
Loosen
nut
bracket
(22) from front axle.
&
Bracket:
Hub shaft
I)
(201,
pull out
shaft
(211,
then
29 kg
assembly
Loosen bolt (23) and remove
cover (24).
remove
2)
Loosen bolt (25) and remove
3)
Sling housing
(28).
washer
(27) and remove
(26).
it from
hub shaft
ASSEMBLY
ASSEMBLY
1.
OF FRONT
AXLE
Hub shaft assembly

1)
Install
housing
2)
Adjust
rotating
(27) to hub shaft
(28).
torque
(30) and tighten bolts (25) with

(26) so that it starts to rotate at 294 to
343 N (30 to 35 kg), as measured by a spring
Insert
shims
washers
balance
0 hooked
Turn the shaft

l
Loosen
bolt
to hub bolt (29).
at least 3 times
(25) and
pull
that it can start to rotate
left and right.
out
shims
(30) so
at 147 to 196 N (15 to
20 kg).
l
Measure
the rotating
ing hub shaft

roller
fits
force
3 times
well.
Then
again
after
rotat-
and after the bearing

bend
lock
plate
(31)
securely.
l
Adjust
perature
3)
the
preload
becomes
after
the
normal.
install cover (24) with bolts (23).
bearing
tem-
2. Bracket
Serial No.: 11001 12502
Serial No.: 11001
023502
1) Assemble bracket (22) to front axle (4), and

insert shaft (21).
2 Shaft and shaft insertion portion:
Grease (G2-LI)
2) Insert lock (21A) into groove [A] of shaft
(21), then assemble collar, bolt, and nut
(21B), (21C), (21D), (21E), and (21F) temporarily. (Do not assemble shim (21G).)
3) Measure clearance [B].
Standard clearance: 1.5 mm
4) Insert shim of thickness [B] + 0.2 mm, then
assemble.
3 Bolt (21D):
343 427 Nm {35 43.5 kgm}
a Standard shim thickness: 1.7 mm
a Types of shims:
t = 0.1 mm, t = 0.5 mm, t = 1.0 mm
5) Insert nut (20) to shaft (21).
3 Nut: 490 608 Nm {50 62 kgm}

1) Assemble bracket (22) to front axle (4), and
insert shaft (21).
2 Shaft and shaft insertion portion:
Grease (G2-LI)
2) Install nut (20) to shaft (21).
3 Nut: 490 608 Nm {50 62 kgm}
30-122
(6)
Serial No.: 11001 12502
023502
3. King pin
1) Assemble hub shaft assembly (6) and bearing (33) to bracket (22), then insert king pin
(19).
2) Measure clearance (C).
a Standard clearance: 6 mm
3) Select one thrust washer of a thickness
closest to (C) 0.2 mm.
a Types of thrust washer:
t = 4.5 mm, t = 5.5 mm, t = 6.5 mm
4) Pull out king pin (19), and assemble
selected thrust washer (32) to bracket (22).
5) Insert king pin into hub shaft assembly and
bracket, insert bolt into hole [1] and secure.
3 Stopper bolt:
59 74 Nm {6.0 7.5 kgm}
30-123
(6)
023502
30-124
(6)
023502
30-124-1
(6)
DISASSEMBLY
VALVE
t
Cleanliness
steering
is extremely
control
disconnecting
oughly.
unit.
the
from
Although
around
procedures
port
exterior
that
disassembly.
explained
the
Follow
throughout
thor-
material
of the unit.
the unit
keep
Before
of unit
foreign
joints
show
you
repairing
area.
area
to remove
not all drawings
during
when
in a clean
clean
brush
recommended
vise
important
Work
lines,
Use a wire
and debris
we
OF STEERING
in a vise,
unit
the
in the
clamping
the manual.
Rotor (Gerotor) End

1. Clamp
edges
unit
in vise
0,
of mounting
vise jaws.
rotor
area.
end
Use
Do not overtighten
up. Clamp
protective
lightly
on
material
on
jaws.
23EFO
2.
Remove
cap screw
3.
Remove
end cap (2).
4.
Remove
seal (3) from
5.
Remove
rotor
6.
Remove
seal (5) from
7.
I lOi
(1).
end cap.
(4). Be careful
Remove
drive
cm3/rev.
displacement
not to drop star.
rotor.
spacer(s)
(6) (not
used
on 49 and
73
units).
23EFOI
302
109
25
(7).
8. Remove
drive
9. Remove
spacer
10. Remove
(8).
plate
(10).
housing
seal (9) from
End
Control
11. Remove
from
cloth
to protect
bladed
screwdriver
housing
(10).
pry
to
ring
retaining
Use a thin
finish.
surface
on
housing
Place
vise.
housing
soft
clean
(11)
from
23EFOI
I I I
12. Rotate spool and sleeve until pin is horizontal.

spool
Push
thumbs
from
sleeve
far
enough
just
Remove
housing.
to
with
forward
assembly
and
gland
free
bushing
your
(12)
bushing.
I
13. Remove
quad
ring
seal
(13) from
seal
gland
23EFOI
I I2
bush-
ing.
14. Use
from
a thin
bladed
seal gland
screwdriver
bushing.
to
pry
Do not damage
dust
seal
(14)
bushing.
23EFOI
I13
15. Remove
2 bearing
bearing
(16) from
races
spool
(15) and
the
and sleeve
needle
thrust
assembly.
23EFOI
16. Remove
spool
and
sleeve
assembly
from
14
II4
hole
end of housing.
*
Do
not
bind
spool
and
from
housing.
spool
sleeve
17. Push pin (18) from
18. Push
spool
then
and
spool
partially
remove
(20) carefully
spool
back
slowly
when
21. Remove
set screw
pliers,
23. Remove
24. Tip
end
springs
(24).
and
removing
seal (22) from
a #IO
Rotate
removing
assembly
control
through
20. Remove
seat
and sleeve
from
housing.
when
(17).
of sleeve
(21)
from
(19),
spool
by hand.
spool
ball
in
slowly
centering
19. Push
22. Screw
sleeve
assembly
of sleeve.
Rotate
sleeve.
housing.
(23) from
housing.
24 machine
Then
out
from
by
screw
pulling
into
on
end
of check
screw,
with
lift seat out of housing.

2 seals (25) from
housing
ball retainer
to
remove
check valve
check
ball
seat.
(27)
and
check
(28).
23EFOI
II7
ASSEMBLY
VALVE
*
Check
all
have
mating
surfaces.
scratches
Clean
air.
OF STEERING
or
all metal
Do not
parts
wipe
that
with
lint or other
matter
system
and cause
damage.
Lubricate
all seals
Do not
(with
exception
jelly
clean
not
excessive
Blow
dry
paper
into
that
leakage.
with
towel
the
be-
hydraulic
use a coarse
grit
parts.
petroleum
seal) with
use
or
can get
these
parts
cause
solvent.
cloth
cause
any
could
in clean
dry
or try to file or grind

*
Replace
burrs
of new
such
lubricant
guad
ring
as Vaseline.
on
seals
for
Do
meter
section.
A good
service
policy
is to replace
all old seals
with
new seals.
Control end
1.
Use a pincette
check
valve
straight
2.
3.
Install
to
check
12.9
Lubricate
fore
on edge)
diameter
ball
seat
do not twist
Install
ference,
fore
6.
to
that
and
sets
have
Test
for
11.1
diameter
thoroughly
be-
installing
seat
When
Install
check
of seat
first.
allen
wrench
ball seat
Push
check
kgm).
of set
screw
to torque
prevent
inter-
is slightly
be-
and
sleeve
carefully
so
(19)
line up at the same

parts
together.
identification
free
in sleeve
To
rotation.
with
finger
Some
marks,
Spool
tip
end.
Rotate
spool
and
align
should
force
these
rotate
applied
at
end.
a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring
b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification
30228
is
surface.
(20)
sliding
(1.2
top
slots
marks.
seals
seals.
end
Nm
sure
sleeve
splined
(28) into
retainer
ball seat (24).
Use a l/4
spool
while
smoothly
seat
mounting
the spring
spool
sure
of hole.
11.8
make
housing
Assemble
retainer
(25) and
in housing.
open
set screw.
screw
seal
or damage
insert
ball seat to bottom
set
ball
Make
in housing.
seals on check
check
installing
in housing,
5.
housing.
ball (27) in housing.
seal (26). Install

4.
of
(not tilted
Lubricate
lower-check
hole
slot
marks.
23EFOI
I IS
7. Bring
spring
parts
slots
on end
tool
through
able
spring
as part
ing
springs
together.
In this
slots
spool
installation
insert
end
Tool
on
arched
installation
stand
is avail-
of center-
bench
center
one
so that
section
end
of
is
entire
tool.
of centering
sleeve
and
3 pairs
of 3 each)
and
line
(21) installation
parts.
Position
position,
extended
into
in
spring
of both
is down
set into spring
8. Compress
parts
Insert
(or 2 sets
edge
push
both
No. 600057.
extended
spring
of
of bench.
assembly
spring
(17)
set and
19
withdrawing
tool at the same time.
ZBEFO
9. Center
the
down
spring
evenly
spool
set in the
and
flush
(20) and sleeve
10. Install
pin
(18)
parts
with
so that
the
they
upper
I I20
push
surface
of
(19).
through
(17) until pin becomes
spool
and
sleeve
assembly
flush at both sides of sleeve.
si
11. Position
the
the splined
of housing
*
spool
with
housing
the
bore
or
14
hole
assembly
cross
pin
the
flush
12. Place
bearing
I I22
23EF0
I I23
end
parts
do not tilt out
parts
gently
keep
pin
assembly
the
end
parts
of
are
dropping
into
the
With
check
the
for
spool
free
with
light
clean,
lint
not
to
the
meter
pull
prevent
the
the
discharge
groove
assembly
in
rotation
finger
horizon-
at the
Do
point
of
place
within
flush
housing.
into
nearly
entirely
this
by turning
within
tip
force
lO---
this
the
at the
end.
housing
diameter
13. Install
from
position,
splined
14 hole
the
the
beyond
housing.
housing
23EFO
(17) so that
assembly
enters
Push
action,
spool
until
spool
of
that
inserting.
rotating
Bring
end
careful
while
slight
tal.
sleeve
121
(10) first.
Be extremely
position
and
end on the spool
23EFOI
on
seal (22) in housing

2 bearing
races
(15)
free
cloth.
Install
54.0
(IO).
and
the
needle
thrust
(16) in the order.
14. Install
or
dust
seal
smooth
wards
(14) in seal
side
of
dust
gland
seal
bushing
must
(12), flat
face
down
to-
f==b
bushing.
15. Install
dry
(12).
Smooth
quad
seal
ring
in
seal
place
with
any seal that falls freely

16. Install
seal gland
twisting
motion.
rubber
hammer.
against
bushing
tap
around
ring
entire
finger.
bushing
Do not
use
of buhisng.
the
spool
bushing
sure
gland
in
that
end with
place
with
bushing
is
flush
23EFO
race.
ring
on
over
the
Make
retaining
ring,
your
into pocket
Tap
the bearing
17. Install
(13) in seal
(11)
end
in housing.
or
pry
circumference
11
After
with
of ring
I I.24
installing
screwdriver
to properly
A
seat
ring in grove.
23EF 01
18. Clamp
housing
mounting
*
Check
in vise.
to insure
that
the
or slightly
below
the
Clean
upper
surface
with
the
the
surfaces
when
Clamp
palm
of clean
of the
meter
ready
for
spool
14 hole
section
reassembly.
edges
of
jaws.
and
sleeve
surface
of the
hand.
on
lightly
area. Do not over tighten
125
housing
Clean
each
parts
Do
are flush
of the
housing.
by
wiping
of the
in a similar
not
use
cloth
flat
way
or
paper to clean surfaces.
23EF0
19. Install 76.2 diameter

20. Install
spacer
plate
plate with tapped
I I26
seal (9) in housing.

(8). Align
bolts
holes
in spacer
holes in housing.
23EF0
I I27
21. Rotate
spool
parrallel
sure
and
with
sleeve
port
face
you
engage
drive
alignment,
mark
drive.
slotted
end
of
drive
to
assembly
a.
until
Install
with
pin.
Note
pin
drive
To
assure
relationship
splined
(18)
(7),
end
of
is
make
proper
between
drive
when
marking.
22. Install
76.2 diameter
23. With
seal
side
star valleys
Note
the
seal (5) in meter
of
meter
toward
(4).
spacer
plate,
23EFOI
23EF0
129
align
(X) (ref. A) on drive (Y) (ref. B).

parallel
relationship
of reference
lines
A, B,
C and D.
Align
bolt
holes
without
disengaging
meter
from
drive.
24. Install
drive
spacer(s)
25. Install
76.2 diameter
(6) when
screws
cap
screws
to 14.7 Nm
used, in meter.
seal (3) in end cap (2).
26. Install end tap on gerotor,

27. Install
I I30
align holes.
(1)
in
(1.5 kgm),
end
then
27.5 Nm (2.8 kgm) in the sequence
cap.
torque
shown
Pretighten
screws
to
in Fig.
23EFOI
I31
F23EH01212
30-G31
ASSEMBLY
1.
Remove bolt (1) holder (2) an collar @ in order.
2.
Remove spacer (3). sprocket

order.
(4) and collar (5) in
There are two types of wheel brake. In the other

type, collar (5) must be removed before the
sprocket.
(The photograph shows the rear left and front
right.)
3.
Remove 4 bolts (6) then remove support (7).
4.
Remove plates (81, discs (9) in order.

+
Plate: 9 PCS,disc: 8 pcs
5.
Remove gear (I 0).
6.
Remove
spacer (1 1).
7.
Remove
guide bolts @
(Thread dia. = 10 mm, pitch

= 95 mm), th*en sling cage assem-
1.5 mm, length
bly (12) and remove
&
kg
8.
it.
Cage assembly:
Remove
6 bolts
(13).
80 kg
6 springs
(14)
then
remove
piston (15).
*
If air is blown in to raise the piston, it is easier to

remove. Be careful not to damage the O-ring or
the sliding surface
9.
Remove
10. Pull out
O-rings
bearing
of the piston.
(16) and (17) from piston (15).

(18)
and
spacer
(19)
from
shaft
assembly.
P2350
1,406
30-l 33
0
ASSEMBLY
ASSEMBLY
1.
BRAKE
Fit O-ring to shaft and install spacer (I 9).

AD+
O-ring groove
2.
Press-fit
3.
Fit O-rings
a
4.
OF WHEEL
bearing
part:
(G2-LI)
(18).
(I 6) and (I 7) to piston.
O-ring groove part:
Press-fit
Grease
bearing
outer
Grease (G2-LI)
race (20)
and oil seal (21)
to
cage.
a
5.
Oil seal:
Grease (G2-LI)
Insert piston (15) slowly to cage (22)

a*,2
Inner
surface
portion)
of
cage
Rust prevention
AMITY=
Sliding surface
AC&
Machined
part
of piston:
(except
inside cage in contact
(non-machined
coating
Grease
for
(PU-4)
(G2-LI)
sliding
surface
with piston:
Rust preventive
Be careful
surface
not to damage
and sliding
when pushing in.
Push the piston

pull back 5 mm.
30234
the O-ring
(KP-I)
in to the end of its stroke,
then
6.
7.
Install 4 springs (14) and 4 bolts (I 3).
ATL
Mounting
bolt:
Mounting
bolt: 49.0 Nm (5.0 kgm)
Blow in compressed
port
air through
@ and move
times
to check
Thread
piston
tightener
cage brake piping air
up and down
that piston
(LT-2)
is returned
two or three
to stroke
end
by the force of the four springs.
8.
After
two
checking
springs
procedure
9.
To
bolts
(13)
remaining
according
to
(I 2) and install to shaft.
Cage assembly:
prevent
of pistion, tighten
and two
in step 6.
Sling cage assembly
& kg
10
operation
(I 4)
misalignment
80 kg
of cage
and shaft,
four guide bolts @ (I 0 mm x 1.5 mm -
11. Install spacer (1 1).
install
95 mm).
12. Install gear (I 0).
13. Install plates (81, discs (9) in order.

*
Plate: 9 PCS,disc: 8 PCS.
14. Fit 2 O-rings to support (7) then install them to cage

with 4 bolts (6).
15. Install collar (51, sprocket (4). spacer (3) in order.
A There
are two types of wheel brake. In the other

type, collar (5) must be installed after the sprocket.
(The photograph shows the rear left and front right.)
16. Install collar @ (c$ 95 mm) then temporarily install

holder (2) with bolts (1).
302 36
DISASSEMBLY
REMOVAL
AIR TANK
AND ASSEMBLY
OF AIR TANK
Lower the work equipment

ground and stop the engine.
completely
1. Disconnect the cable from the negative

to the
ter-
2.
Depress brake pedal several times to completely

release compressed air in air tank.
3.
Remove
4.
Disconnect
tank.
5.
Remove
6.
Disconnect
outer panels (IA)
and (IB).
5 air hoses (I) at bottom
right of air
clips (2) and (3).

wiring
connectors
(4), (5), (6), and
(7).
zz
z
8
7.
Remove wiring harness from

8.
Remove wiring connector

No.: 11013 and up)
9.
Sling air tank assembly

(11) and remove.
INSTALLATION
ASSEMBLY
.
Carry out
removal.
installation
welding
(9) from
(IO), then
clip (8).
clip. (Serial
loosen
235CDO2068
bolt
OF AIR TANK
in the
reverse
order
to
Serial No.: 11013 and
To
transmission
UD
DWG00233
REMOVAL
TANK
1.
Disconnect
2.
Remove
w
OF HYDRAULIC
cable from
drain
negative
(-)
plug (1) and drain oil.
Hydraulic
terminal
of battery.
oil: 108 Q
3.
Remove
outer
panels
4.
Remove
clip (2).
5.
Disconnect
wiring
6.
Disconnect
hydraulic
hoses (5), (6), (7), (8), and (9).
7.
Disconnect
hydraulic
hoses
8.
Sling
hydraulic
(IA)
and (IB).
connectors
tank
(3) and (4).

1235FO2244
/I
(IO), (1 I), and (12).
(13), then
loosen
bolts
(14) and
remove.
INSTALLATION
TANK
l
Carry out installation

Tighten
the
OF HYDRAULIC
in the reverse
drain
plug
order
and
through
the oil filler to the specified
Hydraulic
tank:
to removal.
add
engine
oil
level.
108 R
235COO2
REMOVAL OF HYDRAULIC
PUMP ASSEMBLY
Lower
work
1. Disconnect
equipment
cable
from
completely
negative
(-)
to the ground.
terminal
of bat-
tery.
2. Loosen
drain
hydraulic
I
plug
Hydraulic
3. Remove
(1) and
drain
oil
from
tank:
108 Q
air tank.
For details,
see REMOVAL
4. Disconnect
hoses
draulic
(2).
pump
(3),
OF AIR TANK ASSEMBLY.
(4), (5),
(6), and
(7) from
clip (9) from
pump.
5. Remove
bolt (8), then remove
6. Remove
bolts (IO), and disconnect
7. Remove
bolts
transmission
(12),
pump
Remove
bolts
(13).
*
The
pump
the
remove
are few
(11).
tube
(14)
transmission
with
hose
not to damage
pump,
bottom
to loosen,
disconnect
is removed
hydraulic
(19).
*
There
and
flange
hy-
from
(13).
(15), then
so be careful
9. Sling
hydraulic
tank.
and
spacers
for
pump,
so modify
the
installed,
the hose.
remove
of the
(16)
pump
the
and
mounting
mounting
they
t portion
are
bolts
bolts
at
difficult
of spanner
(make it 7.0 mm) to loosen.

10. Remove
hydraulic
pump
Hydraulic
pump
(2).
assembly:
106 kg
Rear
235CD0207t
trame
235C002074
INSTALLATION OF HYDRAULIC
PUMP ASSEMBLY
1. Set
hydraulic
tighten
*
pump
(2)
in
mounting
position,
and
bolts (19).
There
the
are few
bottom
spacers
of the
to tighten,
so
for
the
pump,
modify
mounting
and
the
they
portion
in
mounting
bolts
are
at
difficult
of spanner
A (make it 7.0 mm) to tighten.

2. Set
transmission
and tighten
3. Install tube
4. Connect
pump
(13)
position,
bolts (15).
(14), and tighten
hoses
bolts (12).
(3), (4), (5), (6), and
(7) to
hydraulic
w-w (2).
5. Install clip (9) to pump.
6. Install flange
(11) to pump.
7. Bleed air from hydraulic

For
details,
pump.
see
BLEEDING
AIR
see
INSTALLATION
FROM
HYDRAULIC
PUMP.
8. Install air tank.
For
details,
OF AIR
TANK
SEMBLY.
9. Add hydraulic
Qz
10. Connect
oil to hydraulic
Hydraulic
tank:
AS-
F23501322
tank.
108 Q
cable to negative
(-)
terminal
of battery.
Reartram
30- 140
0
235CDO2074
BLEEDING
AIR FROM
When
the
HYDRAULIC
hydraulic
replaced
or
pump
removed,
or
PUMP
piping
always
have
bleed
been
the
air
as
engine
oil
follows.
1.
Bleeding
air from hydraulic
1)
Remove
plugs
2)
Disconnect
pump case
(2) and (3).
hose
(1); and fill hose
with
(EO SAEI OW).

Oil: 3.5 - 4 Q
Q
3)
When
oil comes
plugs
2.
from
Bleeding
air from hydraulic
1) Start
engine,
blade
and
lift cylinders
2) Run engine
at
left and right

3)
Run
comes
4)
Run
lift
1.
2.
3.
4.
Hose
Plug
Plug
Plug
(for
(for
(for
(for
at
circuit
to specified
idling,
low
that
lower
left
raise
and
right
and
lower
3 times.
loosen
oil
with
plug
no
(4)
foam
plug.
idling,
to
tighten
3 times.
2 -
idling,
end
at hydraulic
oil
2 -
and
clean
low
cylinders
engine
and
lift cylinders
out, then tighten
air from
Add
at
port,
hose (1).
pump piping
raise
high
check
engine
blade
5)
air bleed
at low idling
blade
engine
slightly,
out
(2) and (3), then install
raise
of
left
stroke,
and
right
and
bleed
hydraulic
tank
relief.
(EO SAEIOW)
level.
draining oil from pump Case)

bleeding air from front pump)
bleeding air from rear pump)
bleeding air)
to
DISASSEMBLY
Special
OF HYDRAULIC
PUMP ASSEMBLY
tools
1.
Draining
oil, cleaning
Raise
pump,
put
then remove
W
oil container
drain
Hydraulic
The drained
pump:
Fit removed
plug
covers
livery
*
blind
Approx.
oil cannot
and
fit
The
plugs
from
(I),
plug,
3 S?
be used again.
and
blind
plugs
(4) to suction
and
blind
entering
the
so they can be fitted

Clean pump
fitted
drain
(2) again,
port
and
de-
port.
dirt
After
under
plug (I), and drain oil.
with flushing
cleaning,
remove
covers
are
pump
during
to
prevent
cleaning,
simply.
oil.
plugs
and
blind
covers
at Item 2).
235CDO2076
2.
Seal assembly
1)
Remove
snap
bly (6) from

*
The
ring
front
(5), then
remove
seal
stationary
seal
and
O-ring
cannot
used again.
2)
Remove
*
rotating
The rotating
assem-
cover.
seal (7) at front

seal cannot
shaft end.
be used again.
be
3.
LS valve (common for F and R pumps)

Loosen
*
5 bolts
Loosen
(1 I), then remove
bolts
in the
order
LS valve
shown
(IO).
in the
diagram
on the right.
235FO2246
4.
Servo
1)
valve assembly
Loosen
raise
plug
servo
(common
(12), and
valve
for F and R pumps)
remove
assembly
6 bolts
(13), then
(14) straight
up and
remove.
2)
Remove
*
5.
gasket
(15).
The gasket
cannot
be used again.
Front pump
1)
Loosen
8 bolts
bolts marked
2)
Loosen
pump
*
(16), then
2 bolts
and center
The
marked
% in turn,
surface
scratched,
the pump
bolts
leaving
in position.
and
separate
section.
mounting
easily
remove
% remaining
when
of the
so put
carrying
servo
a rubber
valve
mat
is
under
out the operation.
P2350
3)
Pull
out
(18).
If the
*
front
pump
pump
does
of the
spring
it with
a plastic
and
(17)
from
not come
cannot
hammer
center
out
by the force
be pulled
to remove
section
it.
out,
tap
I 529
F2350133i
4)
Remove
*
5)
gasket
Remove
6)
(19).
The gasket
be used again.
1lA
2 pins (19A).
Remove
shown
cannot
valve
plate
(20) with
in the diagram
The
mating
center
surface
section
careful
is
of
7)
Remove
Pull out coupling
the
lapped
not to scratch
8)
screwdriver
as
on the right.
valve
plate
precisely,
so
and
be
it.
pin (20A).
(21).
Ll
F23501333
9)
Remove
*
bearing
Make
position
6.
marks
to indicate
of the bearing
the
assembly
cup and shim.
Rear pump
Remove
Front
7.
cup (22) and shim (23).
match
rear
pump
in
the
Disassembly
of front pump
1)
pump
Set front
*
30244
way
as
Item
5.
(24) on stand 0.
Set the front
pump
ful not to let bearing

2)
same
pump.
Remove
O-ring
together
in position
and
be care-
plate (27) fall.

with
backup
ring (26).
3)
Remove
bearing
plate (27) with
mating
surface
The
bearing
plate
is lapped
ful not to scratch
4)
Remove
pilot (28).
mating
The
pilot
scratch
5)
6)
tool
and
so be care-
of the cylinder
precisely,
block
so be careful
and
not to
it.
Pull out pin (29) with
install
precisely,
0.
block
it.
surface
is lapped
screwdriver
of the cylinder
pliers.
A to bearing,
and
pull
out
using
pul-
ler 0.
7)
Remove
*
bearing
Make
position
8)
Remove
(30) and spacer
match
marks
of the bearing.
guide
(32).
(31).
to indicate
the
assembly
9) Remove
pump
from
stand
and
set so that
shaft
is horizontal.
10) Rotate
cylinder
out
Pull
9 piston
11) Loosen
block
the
kit (33) and pull out.
cylinder
block
kit together
with
assemblies.
bolts
(34),
and
remove
front
cover
(35).
P23501541
12) Remove
*
gasket
The gasket
13) Pull out front

14) Set front
rection
*
The
(36).
cannot
shaft (37) from
shaft
of arrow,
bearing
in press,
housing.
push
then remove
is press
do not disassemble
30- 146
be used again.
down
bearing
fitted
it unless
to
shaft
in di-
(38).
the
necessary.
shaft,
so
8
k=G
8
15) Loosen
with
3 bolts
hammer
(39), then
X,
and
tap
bottom
remove
of trunnion
trunnion
assembly
(40).
Make
match
position
16) Remove
marks
to indicate
the
mounting
of the trunnion.
shim
(41) and
O-ring
(42) from
trunnion
assembly.
Check
the
number
and
thickness
shims,
*
The O-ring
cannot
of
the
be used again.
P23508547
17) Pull
out
swash
plate
assembly
(43)
from
hous-
ing.
*
Make
match
position
18) Insert
swash
handle
plate
marks
of hammer
(43), then
(44) lightly,
and remove.
removing
When
to indicate
of the swash
into
push
edge
the
not to drop or scratch
the
mounting
center
hole
plate.
thrust
it.
of thrust
plate,
of
plate
be careful
19) Remove
snap
then remove
8.
ring
(45)
Disassembly
of rear pump
Disassemble
rear
pump
in Item 7. Disassembly
*
There
are
some
pump
Disassembly
of cylinder
retainer
2)
from
cylinder
Pull
out
(47).
*
The
plate
(43),
block
3)
Remove
guide
Remove
6 springs
as shown
in the
shape
of the
and rear pump.
together
assemblies
and
4)
way
with
pistons
kit.
9 piston
piston
same
block kit
(47)
slipper
so do not disassemble
30-&48
swash
pump.
differences
1)
Remove
in the
of front
parts for the front
9.
from
pin (46).
(49).
(50).
(48) from
are caulked
them.
retainer
together,
5)
6)
Set bolt
in vice,
, then
insert
spacer
remove
snap ring (52).
Remove
retainer
tighten
(53),
cylinder
nut
spring
(54),
block
(51) and
slightly,
and
seat
and
(55)
in turn.
10. Disassembly
1)
Remove
of servo valve assembly

O-ring
(79) and back-up
ring (80).
235COO2078
2)
Remove
plug (69).
3)
Remove
t
4 control
Remove
cover
only
the
mounting
4 bolts
bolts (81).
marked
81
in the
diagram.
3
dL
O\
-\
235CW2CBZ
4)
Loosen
remaining
bolts
(81) in turn
cover
(61).
Remove
from
control
gradually,
the
flying
cover
cover
and
carefully
off under
the
Remove
gasket
(62).
6)
Remove
O-ring
(72) and back-up
30250
control
to prevent
pressure
spring.
5)
mounting
remove
ring (73)
it
of the
235FO2247
7) Remove
spring
(63).
8) Remove
piston
(65).
235CDO2084
9) Remove
spring
(84).
235CDO2086
10) Set
housing
(60) at an angle,
and
remove
spool
60
(83).
Be careful
not to damage
11) Hold link (76) in position,

*
Bolt
(71)
cannot
the spool.
and loosen
be
83
reused
bolt (71).
more
than
times.
*
Use a jig for holding
the link.
235CD02087
66
71
u
235FO2248
12) Remove
link (76)
13) Remove
servo
14) Remove
2 pins (67).
15) Remove
piston
taper
plug
(66).
(77),
remove
then
spring
(76).
16) Remove
*
pin (74).
Use long-nosed
pliers to remove.
Long-nosed
pliers
235F0224E
17) Remove
sleeve
(64) from
cover
18) Remove
O-ring
(82) from
sleeve
(61).
(64).
6432
19) Remove
plug (68) from
cover
(61).
68
\
\l\
20) Remove
plug (68A).
61
I
235COO2096
21) Remove
plug (77).
::!2
0
77
--
--A
235CD02097
11. Disassembly
1)
Remove
of LS valve assembly
3 O-rings
(94).
235CD02098
2)
Remove
*
plug (90).
If it is necessary
to
the vice at the position
use
a vice,
shown
clamp
with
by the arrow.
Mating surface
T-4
3)
Remove
spring
(92), spool
235FO2251
(87), spring
seat
(89)
and (93).
235FO2252
302 54
4)
Remove
t
plug (85).
If it is necessary
to use a vice, clamp with

the vice at the position shown by the arrow.
Mating surface
235FO2251
5)
Remove
O-ring
(91) from
plug (90).
6)
Remove
O-ring
(86) from
plug (85).
7)
Remove
3 plugs
235CD0210(
(68).
235FO225L
ASSEMBLY
Special
OF HYDRAULIC
tools
I
I
Part No.
Part name
790-445-6520
Push tool
790-445-6530
790-445-6540
Bar
Coupling
c I
790-445-6550
PUMP ASSEMBLY
A
A.
A
When
assembling,
The
O-ring,
1
1
1
the
sliding
surfaces
of
oil (CLASS CD, SAEIOW).

and
backup
ring
cannot
be
used again.
When
using
vice,
do not grip
the
lapped
surface
of parts.
When
tightening
the parts;
When
The
the
vice,
be careful
use the minimum
replacing
and outer
coat
engine
form
1 Guide
all parts with

gasket,
Qty
the
bearing,
not
to
force
needed.
replace
the
decone
race as a pair.
rotating
seal
and
stationary
seal
cannot
be
used again.
1.
Assembly
Using
front
2.
cover
Assembly
Using
of front cover
push
8,
press
fit
bearing
outer
race
in
fit
bearing
outer
race
in
press.
of rear cover
push
rear cover
tool
(59) with
tool
@, press
(6.0) with
press.
P
3.
Assembly
of front and rear shafts
1)
fit
bearing
(61)
to
front
shaft
(64)
with
fit
bearing
(61)
to
rear
shaft
(65)
with
Press
press.
2)
Press
press.
*
When
replacing
the outer
4.
Assembly
Assembly
Press fit
with
bearing,
replace
it with
of trunnion
Press fit bearing
5.
the
race as a pair.
(62) in trunnion
of swash
bearing
press.
(40) with
press.
plate
outer
race
(63) in swash
plate
(43)
6.
of seal assembly
Assembly
1)
Install O-ring
&
*
(67) to rotating
O-ring:
The
seal
Grease
seal (66).
(G2-LI)
is precision
finished,
so
handle
it
carefully.
*
The seal cannot
The O-ring
be used again.
cannot
be used again.
66
_,?2350
2)
Install
1 pin
(69)
and
6 springs
(70) to
i 665
retainer
(68).
P2350
3)
Install O-ring
(71) to retainer
O-ring:
The O-ring
Grease
I566
(68).
(G2-LI)
cannot
be used again.
P.2350 I567
-,
.....
_._..-..-.
Rotating
seal
_._..
\,
is not assembled
t
The
seal
-,
._
._
_..._.
(66) is installed
is precision
The seal cannot
pump;
it
handle
it
to the seal assembly.

finished,
carefully.
*
\--,.
to the
be used again.
so
7.
Assembly
1)
of cylinder
*,*
block kit
Set bolt @ in vice, and insert cylinder
block (51)
to bolt 0.
2)
Assemble
*
seat (55).
Install
the
seat with
the tapered
side facing
down.
3)
Install spring (54) and retainer

*
Install the retainer

ing up.
(53).
with the stepped
side fac-
5)
Install 6 springs
6)
Install guide
When
of
(50).
(49).
installing
cylinder
guide
b: No tooth
8)
Install 9 piston
Install
semblies
30-A60
(49),
(51)
(49) in a straight
a: Undersize
7)
guide
block
retainer
Cylinder
Piston
spline
spline
a
of
line.
1 place
1 place
assemblies
(47)
to cylinder
&
align
and
(48) to retainer
together
with
block.
block bore:
assembly:
EO SAEIOW
EO SAEIOW
(47).
piston
as-
8.
Assembly
1)
of pump (common
Install
with
2)
pin
(46)
for F and R pumps)
swash
plate
(43),
and
secure
snap ring (45).
Set swash
plate assembly
the
Install
as when
3)
to
Install
swash
(43) in housing.
plate
in the
same
position
disassembling.
O-ring
(42) and
shim
(41) to trunnion
as-
sembly.
2
%
8
The O-ring
Install
cannot
the
same
be used again.
thickness
of
shim
as was
disassembled.
The
shim
thicknesses
are
distinguished
by
color.
Colors
&
Unit:
and shim thicknesses

Color
Thickness
Amber
0.025
Green
0.075
Blue
0.127
Brown
0.254
Yellow
0.508
O-ring:
Grease
(G2-LI)
mm
ADJUSTING
BEARING
PRELOAD
If any
(40),
swash
and
plate
bearing
just the preload
Install
(43),
(57)
housing
have
(56),
been
trunnion
replaced,
ad-
43
56
of the bearing.
trunnion
clearance
OF TRUNNION
without
shims,
and
measure
d.
Standard
shim
shickness
Clearance
shims
between
0.075 + 0.025 mm.
Remove
right,
*
trunnion,
divide
left
and
and install.
The
difference
thickness
between
should
left
be within
and
right
shim
0.13 mm.
5i
5)
Tighten
*
3 trunnion
Tighten
sition shown
m
mounting
together
with
bolts
=33501337
(39).
bracket
in the diagram
40
(58) in the
po-
on the right.
Bolt: 49.0 Nm (5.0 kgm)
F23501338
6) Install thrust plate (44) to swash plate.

*
Install
the
portion
of
the swash
*
Coat
with
prevent
7)
Coat slipper
engine
thrust
the
plate
outside
with
the
chamfered
circumference
facing
plate.
grease
the thrust
portion
(G2-LI)
when
plate from
of piston
oil (EO SAEI OW).
installing
falling
assembly
to
out.
(48) with
8)
9.
Install
Assembly
1)
cylinder
kit (33) to housing
Align
of the
portion
shaft assembly
missing
tooth
cylinder
f
portion
block
of the
(37)
kit with
spline
Set gasket
*
(36) to housing.
The gasket
cannot
of the spline
missing
of the
assembling.
2)
(56).
of front pump
Install front
block
be used again.
shaft
tooth
when
3)
install
front
cover
assembly
(35)
and
tighten
bolts (34).
m
Bolt: 98.1 + 9.8 Nm (IO f 1 kgm)
Tighten
the
the
order
front
cover
shown
in
mounting
the
diagram
bolts
on
in
the
right.
F23501338
4)
Set front
pump
5)
Install spacer
(31).
6)
Using
tool
push
on stand,
A,
and install guide
press
fit
bearing
(32).
(30)
with
press.
*
When
press
fitting,
be careful
not to damage
the part.
After
press
particles.
3op
fitting,
clean
off
all dirt
and
iron
7)
Install pilot (28).
8)
Install pin (29).
9)
Install bearing
*
Align
plate (27).
pin (29)
and the
installing the bearing

*
Coat
10. Assembly
1)
with
grease
(G2-LI)
hole when
when
installing
to
of rear pump
Install rear shaft assembly
mounting
plate.
Align
missing
of the
portion
tooth
cylinder
f
(73).
portion
block
of the
e of the spline
kit with
spline
missing
of the
tooth
shaft
when
assembling.
2)
,\:: i,,, ,:
Stand rear pump upright.
Lay
rubber
mat
under
the
shaft
to
pre-
,,
vent damage.
P2350
L 585
30265
3)
Install guide
(32).
4)
Install spacer
(31).
5)
Using
tool
push
A,
press
fit. bearing
(30)
with
press.
*
When
press
fitting,
be careful
not tc3 damage
the parts.
*
After
press
fitting,
clean
off
all dirt
and
iron
when
in-
particles.
6)
Set gasket
(36) to housing.
The gasket
Make
sure
stalling
cannot
that
be used again.
the
gasket
is dry
it.
P23501588
7)
Install
rear
mounting
w
cover
bolts
assembly
(74),
and
(75).
Bolt: 98.1 + 9.8 Nm (10 k 1 kgm)
tighten
Tighten
order
the
rear
shown
cover
mounting
in the diagram
bolts
in the
on the right.
F23501340
8) Install
pilot
9) Install
pin (29).
IO) Install
*
(28).
bearing
Align
plate (27).
pin
installing
*
Coat
(29)
and
the
the bearing
with
prevent
grease
the bearing
mounting
hole
when
plate.
(G2-LI)
when
plate from
installing
falling
to
out.
11. Rear pump

1)
Install taper
w
2)
plug (76) to center
Plug:
14.7 Nm (1.5 kgm)
Install shim (23) to rear pump

*
Install
section.
the
same
side.
thickness
of
shim
as
was
disassembled.
3)
Install
*
bearing
Install
as when
*
Coat
cup (22) to rear pump
the
cup
in the
side.
same
position
disassembling.
with
prevent
bearing
grease
the bearing
(G2-LI)
when
cup from
falling
installing
out.
to
4)
Align
valve
plate
(20) with
stall to rear pump

*
The
shape
shown
*
the
grease
from
of
the
rear
in the diagram
Coat
hole
g,
and
in-
valve
is
as
plate
on the right.
rear
surface
(G2-LI)
when
falling
pin
side.
of the valve
plate
installing
prevent
to
with
it
out.
F23501342
5)
Install
pump
*
O-rings
and
backup
rings
(26)
to
rear
at 2 places.
The
O-ring
and
backup
ring
cannot
be used
again.
6)
Install gasket
+
7)
(19).
The gasket
Coat
bearing
cannot
plate
be used again.
(27)
of
rear
pump
with
en-
gine oil (EO SAEl OW).
8)
Stand
section
t
rear
When
center
302
68
pump
(77) upright,
(18) to rear pump

installing,
section
valve
be
from
and
install
center
top.
careful
not
plate fall out.
to
let
the
Method
@
of tightening
Tighten
right
in
bolts
turn
2 bolts
marked
in
diagram
until center
section
(18) is in close contact.
If bolt
becomes
difficult
to tighten
is still
not in close
contact,
but center
loosen
bolts
on
section
and tighten
again.
@
Install
remaining
6 bolts and screw
them
in.
F2350134:
Set
pump
order
m
*
on
shown
its
side,
in diagram
and
tighten
8 bolts
(16)
in
on right.
Bolt: 62.8 f 5.9 Nm (6.4 + 0.6 kgm)

Lay
rubber
damage
mat
under
to the ports when
the
pump
to
prevent
tightening.
F23501344
9)
Measure
i)
Set
shaft end play of rear pump

tool
B to
rear
shaft,
play with dial gauge.

Standard end play: 0.15 ii)
If
measurement
adjust
is
and
measure
end
0.41 mm
outside
standard
shim (23) again in Item 11.2).
End play too large:
Add shims
End play too small:
Remove
shims
range,
F23601345
12. Front pump

1)
Install shim (23) to center

*
Install
the
same
section.
thickness
of
shim
as was
disassembled.
2)
Install
*
bearing
Install
as when
*
Coat
Align
bearing
with
grease
valve
The
plate
with
prevent
when
cup from
(20) with
of
the
pin
front
in the diagram
Coat
same
position
installing
falling
hole
to
out.
g,
and
in-
is
as
section.
shape
shown
section.
in the
(G2-LI)
the bearing
stall to center
*
cup
disassembling.
prevent
3)
cup (22) to center
the
grease
the valve
valve
plate
on the right.
(G2-LI)
when
plate from
installing
falling
to
out.
F23501346
4)
Install coupling
5)
Install
pump
*
(21) to center
O-rings
and
backup
section.
rings
(26)
The
O-ring
and
backup
ring
cannot
again.
6)
Install gasket
*
to
front
at 2 places.
(19).
The gasket
3oi!70
cannot
be used again.
be used
7)
Coat
bearing
plate
(27)
with
engine
oil
(EO
SAEI OW).
8)
Install front
*
valve
Method
@
pump
Be careful
to
let the
section
(18).
bearing
plate
and
diagram
on
plate fall out.
of tightening
Tighten
(17) to center
not
in turn
bolts
2 bolts
marked
in
right until center
section
(18) is in close contact.
If bolt
becomes
difficult
to tighten
is still
not
in close
contact,
but center
loosen
bolts
and
,
section
tighten
again.
0
Install
remaining
6 bolts and screw
them
in.
F23501343
Tighten
8 bolts
(16)
in order
shown
in diagram
on
right.
m
*
Bolt: 62.8 k 5.9 Nm (6.4 + 0.6 kgm)

Lay
a rubber
damage
mat
under
to the ports when
the
pump
to
prevent
tightening.
F23501345
9)
Measure
i)
Set
shaft end play of front

tool
C to front
pump
shaft,
and
measure
end
play with dial gauge.

Standard
ii)
If
end play:
measurement
0.15 is
0.41 mm
outside
standard
range,
adjust shim (23) again in Item 12.1).

End play too large: Add shims
End play too small:
13. Assembly
1)
Remove
shims
of servo valve assembly
Install
w
plug (68) to cover
(61).
Plug: 14.7 Nm (1.5 kgm)
235CD02096
2)
Install
*
To
O-ring
thread
3)
with
Install sleeve
m
302 72
(82) to sleeve
prevent
damage
seal tape before
(64) to cover
Sleeve:
(64).
to the
O-ring,
wrap
the
inserting.
(61).
86.3 Nm (8.8 kgm)
61
64
4)
Install
plug (68A) to housing.
5)
Plug:
Install
14.7 Nm (1.5 kgm)
pin (74) and spring
(78) to housing
with
plug
(77).
m
6)
24.5 Nm (2.5 kgm)
Install
plug (77) to housing.
7)
Set
24.5 Nm (2.5 kgm)
pin
(67) to servo
piston
(66), then
insert
in
housing.
Q
*
Servo
Insert
places)
piston
so
of
piston:
Engine
oil (SAE IOW)
that
the
chamfered
the
large
diameter
are at the top (spring
portions
of
chamber).
the
(2
servo
8)
Install link (76) to servo piston (66).

m
*
Bolt( 71): 111.8 Nm (11.4 kgm)

Use a jig for holding the link.
66
71
LJ
235FO2248
9)
Insert spool (83) in housing (60).

Q
Spool: Engine oil (SAEIOW)
235COO2087
10) Assemble
spring (84) in housing.
8?
235CDO2OBe
11) Assemble
spring (63) in housing.
I
30274
235CDO2084
12) Install
O-ring
(72) and back-up
ring (73).
2?5COO2083
13) Insert
piston
(65) in sleeve
Piston:
Engine
(64).
oil (SAEI OW)
235COO210;
14) Install
gasket
(62) to housing.
235COO2103
15) Install
cover
(61)
to
housing,
and
tighten
with
bolt (81).
*
Be careful
When
bolts
tighten
m
not to let the piston
tightening
on
the
bolts,
diametrically
all the other
drop out.
first
opposite
tighten
two
sides,
then
bolts.
Bolt: 32.4 + 2.9 Nm (3.3 + 0.3 kgm)
235CDO21OL
16) Fit O-ring to plug (69) and install to housing.
17) Install
*
O-ring
(79) and back-up
ring (80).
a small amount
of grease.
Coat with
235COO2078
14. Servo valve assembly

1)
Install
2)
Move
swash
(front
cover
*
3)
plate
for F and R pump)
(43) fully
or rear cover
cannot
in direction
of arrow
side).
be used again.
link h of servo
swash
(common
(15).
The gasket
Align
*
gasket
valve
(14) and
pin i of
plate, then install.
Check
that
backup
rings fitted
The
O-ring
there
and
are
the
O-rings
and
the
to the servo valve.
back-up
ring
cannot
bolts
in
be used
again.
*
Tighten
shown
w
the
mounting
in the diagram
the
order
below.
Bolt: 62.8 + 5.9 Nm (6.4 + 0.6 kgm)
--
F23501349
F23501348
15. LS valve (common

1)
2)
(68).
14.7 Nm (1.5 kgm)
Plug:
Insert spool
*
(87) in housing.
Be careful
correct
3)
for F and R pump)
Install 3 plugs
to
insert
If it is necessary
to
the vice at the position

Insert
spring
holder
(89).
Fit O-ring
w
facing
in the
to housing.
Plug: 23.5 i 7.9 Nm (2.4 + 0.8 kgm)
5)
spool
Fit O-ring to plug (85) and tighten
4)
the
direction.
holder
use
a vice,
shown
clamp
with
by the arrow.
(93), spring
(92), and
to plug (90) and tighten
to housing.
spring
235FO2252
Plug: 122.6 i 9.8 Nm (12.5 f 1.0 kgm)
235FO2251
6)
Install 3 O-rings
(94).
16. Installation
of LS valve
Install LS valve (10) to servo valve with bolt (11).

*
When
installing,
check
that
3 O-rings
are fitted
to the mating surface.

*
See
the
diagram
tightening
m
for
details
of
the
order
for
the bolts.
Bolt: 29.4 -
35.3 Nm (3.0 -
3.6 kgm)
235FO2256
17. Plugs
Install 3 plugs (8).
w
plug: 117.7 + 9.8 Nm (12 &- 1
18. Seal assembly

1)
kgm)
(front side only)
Install rotating seal (7).

*
Do not use dirty
hands
or wear
gloves
for
side with
the
this operation.
2)
Install seal assembly

&
3)
(6).
O-ring: Grease (G2-LI)
Install snap ring (5).

*
Install
the
snap
ring with
curve facing the outside.
the
REMOVAL OF HYDRAULIC
A
1.
Lower
work
equipment
completely
to
the
ground.
Disconnect
cable
from
negative
(-)
terminal
of bat-
tery.
2.
Loosen
w
drain
plug and drain
Hydraulic
tank:
hydraulic
oil.
108 Q
j235FO2244
3.
Remove
control
levers
(2)
from
hydraulic
control
valve.
4.
5.
Remove
Remove
covers
11 hoses
(7), then remove

*
There
(3), (4), and (5) from
are
and
tubes
platform.
(6) from
bolts (IO), and control

13 hoses
and
tubes
control
valve
when
valve
(7).
the
ripper
control
valve
is installed.
6.
Remove
11 hoses
(9), then remove
and
tubes
(8) from
bolts (IO), and control
valve
(9).
/I
INSTALLATION OF HYDRAULIC
1.
Install
control
valve
hoses and tubes

2.
Install
control
valve
hoses and tubes
3.
Install
4.
Install control
5.
6.
Close
covers
drain
(9) with
(8) to control
(7) with
bolts
(IO),
valve
(7).
and
connect
and
connect
(3), (4), and (5) to platform.

levers
plug
(2) to hydraulic
(1) and
(11) to specified
Hydraulic
tank:
cable to negative
the
to
hydraulic
valve.
oil
through
108 II
engine
add
control
level.
Connect
system.
(lo),
(6) to control
oil filler
Run
bolts
valve.(g).
(-)
terminal
circulate
the
of battery.
oil through
the
35FO2257
DISASSEMBLY
Be
careful
to
scratches
Be
check
careful
When
or
that
there
is
CONTROL VALVE
no
dirt
or
not
to
damage
the
sliding
surface
other
the
parts,
spools,
mark
shuttle
valves,
with
tags
to
same valve
9. Pull out spool
to
assemble
10. Remove
be sure
in the
1)
case.
(1) and
(2) with
a box
wrench,
and
nuts
(1)
and
(2)
fitted
to
the
stud
out
2)
Remove
each
valve
Make
match
of each valve
Remove
O-rings
body
assembly
from
stud
5. Loosen
marks
on
the
mating
surface
valve
spring
(22).
fly. off.
plug (23), then pull out spool
(24).
(7) and (8) from

valve
cap (25).
Remove
locknut
(27) from
cap (25).
Remove
collar
valve
assembly
(12),
and
(9).
remove
removing
let the spring

spool
seal (17) with
bolt
collars
a screwdriver.
lever,
be careful
and
backup
plug (32), then pull out spool
not
to
remove
oil
of pilot
relief
ring
(33).
valve
2)
Loosen
cap
(13),
fly off.
(16) towards
(29),
screw
(31).
pilot relief valve
3)
(12),
(with
adjustment
(28), o-ring
Remove
move
(14), and plate (15).
When
(26) and
1)
cap (11).
2
valve
body.
washers
bolt
compensation
screw)
(30), and spring
body.
2 bolts (IO), and remove
6. Loosen
7. Push
compensation
not to let the spring
Remove
13. Disassembly
4. Pull out shuttle
a screwdriver.
screw)
of pressure
Remove
3. Remove
spring
(19).
cap.
cap (21), then remove
Be careful
12. Removal
(5) and (6).
spring
pressure
adjustment
adjustment
bolts.
bolts
plate
nuts (3) and (4).
Leave
2. Pull
of
(without
*
nuts
(16) from
oil seal (20) with
11. Removal
assembling,
loosen
(18), and remove
distin-
guish the location.
1. Hold
2 bolts
surface.
disassembling
any
When
8. Loosen
on any part.
and the mating
OF MAIN
nut
adjustment
assembly
and
nut
screw
(34).
(36), then
(37)
and
reseal
(38).
Be careful
Remove
(35)
spring
and backup
not to let the spring

(40),
valve
ring (43) from
(41),
valve
fly off.
o-ring
body
(39).
(42),
235F501
30;
83
ASSEMBLY
Be
careful
scratches
Be
OF MAIN
to
check
careful
any
not
to
no
dirt
or
damage
the
the
spools,
match
location
the same valve

Replace
sliding
surface
shuttle
with
and
tags
be sure
valves,
used
the
1)
to
assemble
in
backup
rings,
and
spool
(47) to plug
with
engine
oil
valve
(24)
in
valve
body,
then
install
to valve
(23) and
fit
Plug: 78.5 k 9.8 Nm (8 + 1 kgm)
Insert
spring
There
oil seals
(22) in cap (21).
are two
springs
in the
circle
rota-
tion only.
3)
surface
compensation
screw)
Insert
O-rings,
pressure
O-ring
w
2)
case.
sliding
of
adjustment
case.
or
to distin-
new parts.
Coat
3. Assembly
(without
the
parts,
the
with
is
surface.
assembling
other
guish
there
on any part.
and the mating

When
that
CONTROL VALVE
before
Fit
O-ring
valve
(48)
to
cap
(21)
and
install
to
case.
assembling.
m
Assembly
of pilot relief valve
1)
Insert
valve
body
(39),
(41)
and
and
spring
screw
in
(40)
in
valve
adjustment
screw
4. Install
Cap: 78.5 + 9.8 Nm (8 F 1 kgm)

oil seal (20) to valve
&
body.
Lip of oil seal: Grease
(G2-LI)
(37) lightly.
2)
Tighten
nut
2 washers
(35)
to
(38),
nut
adjustment
(36),
screw
and
(37)
cap
tempo-
5. Insert spool
*
(16) in valve
Be careful
body.
not to damage
the oil seal.
rarily.
3)
Install
valve
4)
backup
body
ring
(43)
and
Fit O-ring
(42)
to
relief
(34), and install to valve
case.
Pilot relief valve:
valve
After
adjusting
pilot
relief
the
Bolt: 7.9 k 1.0 Nm (0.8 & 0.1 kgm)
7. Install
68.6 f 9.8 Nm
valve,
2 bolts (18).
assembly
set
pressure
tighten
nut
oil seal (17) to valve
&
(7 * 1 kgm)
*
6. Fit plate (19) and tighten

@El
(44) to pilot
O-ring
(39).
of the
(36)
and
body.
8. Assemble
plate
(14) to valve
(15),
body,
(G2-LI)
2 collars
(13),
then tighten
and
spring
bolt (12).
cap nut (35) fully.

m
Nut: 44.1 + 4.9 Nm (4.5 i
Cap nut: 44.1 14.9
&?YZ
Bolt: Thread
Bolt:
Assembly
of
pressure
(with adjustment
screw)
1)
(33)
Insert
spool
O-ring
(45) to
plug
compensation
11.28 + 1.47 Nm (1.15 k 0.15 kgm)
valve
(32) and
cap (1 I), and tighten
2 bolts
(10).
valve
m
in
(LT-2)
Nm (4.5 + 0.5 kgm)

9. Insert
2.
tightener
0.5 kgm)
body,
then
install
to valve
Bolt: 7.8 + 1.0 Nm (0.8 i
0.1 kgm)
fit
10. Insert shuttle
valve
(9) to each valve
body.
case.
m
2)
Install
collar
3)
backup
ring
Tighten
adjustment
to
(25)
cap
Fit
valve
m
*
and
O-ring
screw
temporarily,
(46)
O-rings
12. Insert
valve
(7) and (8) to each valve
O-ring
(29)
to
(27)
and
and
locknut
insert
body
in
stud
bolts
the same order
as for disassembly.
not
collar
Be careful
let the O-ring
to bend
the
protrude.
(31) in cap.
to
cap
(25)
and
install
to
13. Tighten
nuts (2) and (3).
case.
m
Nut (2): 58.8 Nm (6 kgm)
Nut (3): 98.1 Nm (10 kgm)
Cap: 78.5 f 9.8 Nm (8 k 1 kgm)

Tighten
the
locknut
the set pressure.
3Oi.84
(30)
(28).
(28) and spring

4)
11. Install
body.
Plug: 78.5 & 9.8 Nm (8 k 1 kgm)
fully
after
adjusting
(5) and
shuttle
(6)
valve
in
or
LO
27/
34
235F501
302
85
DISASSEMBLY
OF CIRCLE ROTATION
MOTOR
Serial No.: 11001 - 12050

Special tools
No.
A,
1 790-445-6210
1 * Stand
A,
790-445-6220
/ . Stud bolt
A,
790-445-6230
/ * Stud bolt
A., /
790-445-6240
I * Handle
A,
790-445-6250
) . Nut
A,
01010-31045
1 - Bolt
A,
01643-31032
1 * Washer
I 2
I 4
I 4
A,
04025-00332
I . Spring pin
790-445-6260
I Plate
B,
790-445-6270
I . Plate
B,
01010-31030
1 - Bolt
Part No.
790-445-6200
4
*
1 Stand
assembly
[MY
I 1
I 1
F23501351
I 1
I 5
* Washer
01643-31032
Be careful
Part NekF\c
to check
that
there
is no dirt
or scratches
on any part.
Be
careful
not
the mating
to
damage
1.
Remove
drain
2.
Remove
plug (2) from
3.
Set
shaft
secure
*
plug (1) and drain
facing
with
Install
Insert
from
bolt
5.
sliding
surface
and
put
stud
oil from
F23501352
plate (3).
motor
(As) in the
motor,
hole
(A,), then
on stand
(A,).
for
the
piping
flange
6,
P-l
bolt.
bolt
retainer
secure
up,
retainer
bolt (AJ and washer
mounting
4.
the
surface.
(A,)
plate
with
nut
spring
pin (A&.
Loosen
bolt
(5),
in
hole
of
(3), screw
(A&
and
and
plug
(2)
into
cylinder
install
handle
remove
cover
(6),
removed
block
(4),
(AJ
and
O-ring
(7),
and shim (8).

*
Make
match
marks to cover
(6) and case (9).
F23501353
30-186
0
Be careful
not
shaft when
removing
6. Loosen
bolts
(9) from
7. Fit
(ll),
damge
oil
seal
(IO)
with
the
and
pull
out
case
secure
with
(14)
while
the cover.
(12),
and
(13),
top.
plate
(B,)
to swash
bolt (B,) and washer

8. Using
gear
pulling
*
to
puller,
out inner
Be careful
9. Remove
plate
(14),
and
(BJ
remove
swash
race of bearing
not to let pistons
plate (B,) from
swash
plate
(15).
(16) fall.
plate (14).
I
10. Remove
piston
11. Remove
stud
(16) and springs

bolt
(4), then remove
(A,)
screwed
cylinder
block
Be careful
not to remaining
Be careful
not to let timing
12. Remove
pistons
13. Remove
timing
14. Using
from
gear
retainer
15. Loosen
plate
plates
bolts
(16) inside
puller,
into
block
pistons
(16) fall.
plate (18) fall out.
cylinder
remove
cylinder
F23501354
(4).
plate (18), spring

inner
block
(4).
(19), and pin (20).

race
of bearing
plate
(3) and
(21)
plate (3).
(22) from
(14), then
remove
(24), and slippers
16. Remove
(17) at shaft end.
retainer
retaining
(25).
O-ring (26) from retainer
swash
rings (23), retaining

L
F23501355
plate (3).
F23501356
17. Remove
sleeve
*
O-ring
(27) fitted
Do not
(28)
and
to retainer
remove
backup
ring
(29)
from
plate (3).
sleeve
(27) except
when
replac-
ing it.
18. Remove
block
19. Remove
*
outer
race
of
bearing
(21)
from
cylinder
(4).
Insert
oil seal (10) from

pins
in two
cover
holes
(6).
of the
cover,
and
pull
out the oil seal.
F23501356
F23501357
ASSEMBLY
Serial
OF CIRCLE ROTATION
MOTOR
No.: 11001 - 12050
Special tools
No.
CL3
01643-01232
* Washer
C,
04205-00835
. Pin
C 10
04205-01038
* Pin
C,,
04052-00833
. Snap pin
C 12
04052-01038
. Snap pin
Be careful
to check
that
there
is no dirt
Part No.
Part Name
Qty
790-445-6400
D,
790-445-6410
. Push tool
D*
790-445-6420
. Inserting
790-445-6430
Top hat assy
B,
790-445-6440
. Top hat
E2
01010-31035
. Bolt
B,
01643-31232
. Washer
790-445-6450
F,
790-445-6460
Inserting
Adjusting
tool assy
1
1
tool
tool assy
* Shim adjusting
tool
F,
1 01010-31055
1 . Bolt
F,
1 01643-31032
1 * Washer
I 4
F,
1 01050-31030
1 . Bolt
or scratches
on any part.
Be
careful
the mating
Coat
the
before
Replace
not
to
damage
the
sliding
surface
and
surface.
sliding
surface
with
engine
oil
(EOlO-CD)
assembling.
the O-rings
and oil seals with
new parts.
30-189
0
1.
Fit O-ring
6
(26) to retainer
O-ring:
2.
Knock sleeve
3.
Install
Grease
plate (3).
(G2-LI)
(27) into retainer
backup
ring
(29)
plate (3).
and
O-ring
(28)
to
sleeve
(27) in order.
&
4.
ring, O-ring:
Install
stoppers
taining
ring (23) to retainer
B
5.
Backup
(25),
Grease
retaining
16.n
(G2-LI)
plate
plate (3) with
(24),
and
A---
re-
bolts (22).
25.
Bolt: 5.9 Nm (0.6 kgm)
Shrink
fit inner
race
of bearing
(21) to retainer
plate
(3) to install.
*
6.
7.
Shrink-fitting
Insert spring
Install
Pin: Grease
Put retainer
bolt (4)
9.
plate
plate
plate
(18)
(AJ, and spring
13oC
plate (18).
(G2-LI)
(A,),
and
secure
with
(27), and secure
tim-
(A,).
(18) on sleeve
with
Max.
(27).
(3) on stand
and washer
Put timing
ing
(19) in sleeve
pin (20) to timing
&
8.
temperature:
stud
bolt
(AJ,
nut
(A,),
F23501356
handle
pin (A,).
F23501358
When
assembling
metrically
the
to the
high
side
of retainer
10. Knock
timing
plate
left and
and low
(18),
right
side
set
of the
it sym-
line joining
of the angled
surface
plate (3).
outer
race
of bearing
block
(4) to retainer
(21) into
cylinder
block
(4).
11. Set cylinder
plate
(3) secured
to
stand.
stud bolt (As) holding
12. Remove
13. Fit stud
retainer
*
(A*), and
bolt
slipper
(25) with
of the cylinder
14. Fit piston
s!
z
8
cylinder
(18).
block
(4) and
the
position
of the
bore
block.
rings (30) to pistons
pistons
der block
16. Insert
secure
plate
plate (3).
Align
15. Insert
timing
(16).
(16) at retainer
plate
(3) end
in cylin-
(4).
springs
Set the
(17) in cylinder
piston
at the
block
retainer
F23501356
(4).
plate
end
in posi-
tion securely.
17. Install
*
retention
Align
tools (C, - C,,) to cylinder
stopper
(C,) with
the
position
block
(4).
of the
piston
hole.
18. Using
inserting
at swash
plate
tools
(D,) and
(14) end,
then
(D,),
insert
piston
stop
piston
with
(16)
stop-
per (C,).
F23501359
F23501360
19. Install
slippers
(25),
retaining
ing ring (23) to swash

w
Bolt:
20. Set
swash
(4).
*
Align
(24),
and
retain-
bolts (22).
5.9 Nm (0.6 kgm)

plate
(14)
the thick
tainer
plate
plate (14) with
plate
in
sides
(3) so
position
on
of swash
that
cylinder
plate
they
are
block
(14) and
on
the
re-
same
side.
21. Set top
hat (E,) over
washer
(EJ
tighten
24. Set
shaft,
bolt
then
hole
in
retention
positioning
case
(9)
tools
pin to swash
over
cylinder
&
Bolt: Thread
tightener
Bolt: 78.5 Nm (8 kgm)

seal
washers
(31)
to
case (9) and swash
(E2) and
shaft
to
(14).
block
(4),
then
secure
bolt (13).
(l-T-2)
bolts
(11)
and
(12),
then
plate (14).
Bolt: Thread
Q&z
Bolt: 46.1 Nm (4.7 kgm)
27. Shrink
plate
(3) with
&
26. Remove
of
(C, - C,,).
plate
tighten
bolt
face
F23501361
case (9) and retainer
25. Fit
screw
end
top hat (E,).
22. Remove
23. Install
into
tightener
(LT-2)
top hats (E, - EJ and stud bolt (A,).

fit inner
race
of bearing
(15) to shaft,
then
in-
stall.
*
Shrink-fitting
temperature:
Max.
130C
F23501362
F23501363
28. Knock outer

29. Adjusting
1)
2)
race of bearing
(15) into case (9).
shim
Put
shim
adjusting
tighten
to
washer
(F3).
Tighten
swash
(F,) on
tool
plate
(14)
(F,), and press
3 bolts
case
with
(9),
bolt
fit
and
(F2) and
bearing
outer
race (15).
*
Make sure that it goes down

w
*
3)
uniformly.
Bolt: 9.8 Nm (1 kgm)
Rotate the shaft at the same time.
Using
each
measure
hole
of
clearance
race
and
take
the
end
face
average
shim
adjusting
between
of
of
end
shim
each
face
adjusting
dimension
(F,),
tool
of
outer
tool,
and
as dimen-
sion X.
X=A-B
*
The
each
F23501364
difference
place
of
between
the
dimensions
measurement
shall
at
be within
4)
Measure
dimension
and dimension
When
Y, of shim
Y, of cover
adjusting
(6) when
Calculate
0.1
Y, - Y, = 2 from
mm
(X + Z) and
to
decide
the
add
shim
(F,)
installed.
dimension
X.
Remove
shim adjusting
X.
a preload
thickness,
of 0.05
then
in-
I
15
F23501365
stall the shim.
6)
FI
WhenY,<Y,
Add Y, - Y, = Z to dimension
5)
tool
F4
Y, > Y,
Subtract
F3
F2
0.05 mm.
tool.
F23501366
30. Knock oil seal (10) into cover

&
31. Fit O-ring
32. Install
cover
(G2-LI)
(6).
(7) to cover
O-ring:
&
Grease
(G2-LI)
(6) to case (9) with
bolt (5).
Bolt: 62.8 Nm (6.4 kgm)
w
33. Rotate
*
(6).
34. Install
rotating
shaft, and measure
Rotating
torque:
torque.
6 kgm
plug (2) to retainer
plate (3).
F23501367
F23501368
F23501352
30294
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
Serial
CIRCLE ROTATION
OF CIRCLE ROTATION
MOTOR
MOTOR ASSEMBLY
No.: 12051 and up
1.
2.
3.
4.
5.
6.
7.
Bolt (5 or 7)
IA.
Bolt (7)
IB.
Bolt (7)
IC.
Bolt (7)
End cover
Seal ring
Seal ring
Commutator
Commutator
ring
Manifold
8. Rotor set
8A. Rotor
8B. Stator half
8C. Vane
8D. Stator half
8E. Vane
9. Wear plate
IO. Drive link
11. Thrust bearing
12. Coupling shaft
12A. Key
12B. Nut
12C. Washer
12D. Bolt
12E. Lock washer
12F. Retaining ring
DWG00277
13.
14.
15.
16.
17.
18.
19.
20.
21.
Bearing (inside)
Thrust washer
Thrust bearing
Seal
Backup washer
Housing
Bearing (outside)
Seal
Backup washer
30-194-l
0
DISASSEMBLY
1.
AND ASSEMBLY
CIRCLE ROTATION
MOTOR
Remove
shaft key (12A), bolt (12D), washers
(12E) and (12C), and retaining
ring (12F).
Ir
Polish the area around
the key groove
on
the shaft and remove all burrs and flashes.
DWG00278
2.
Fix motor in vice and make mark to prevent

it
from moving
out of position.
*
Grip the flange portion
of the motor in the
vice.
3.
Remove
7 bolts
4.
Remove
end cover
30-194-2
0
(I) from
end cover
(2).
(2) and seal ring (4).
Mark
DISASSEMBLY
AND ASSEMBLY
5.
Remove
commutator
ring (6).
6.
Remove
commutator
(5) and seal ring (3).
7.
Remove
manifold
CIRCLE ROTATION
MOTOR
(7).
DWGO
8.
Remove rotor set (8) together with wear plate

(9), then remove drive link (IO) and thrust bearing (II).
Lift rotor set (8) up together with the wear
*
plate to prevent the rotor set from coming
apart.
Make a mark to indicate the top surface of
*
the rotor set.
30-194-3
0
DISASSEMBLY
AND ASSEMBLY
9. Pull out coupling
CIRCLE ROTATION
shaft (12) from housing
MOTOR
(18).
10. Pull out inside bearing (13) from housing (18).

Ir Measure the mounting
depth (position) of
bearing (13) and note the measurement.
=,
11. Remove
thrust
bearing
(15) and thrust
washer
(14).
12. Remove
(17).
30-194-4
0
seal (16) and backup washers
(21) and
DWG00287
DISASSEMBLY
AND ASSEMBLY
13. Remove seal (20) and pull out outside

(19) from housing (18).
CIRCLE ROTATION
MOTOR
bearing
30-194-5
0
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
ASSEMBLY
OF CIRCLE ROTATION
MOTOR
MOTOR ASSEMBLY
DWG00277
1.
2.
3.
4.
5.
6.
7.
Bolt (5 or 7)
IA.
Bolt (7)
IB.
Bolt (7)
IC.
Bolt (7)
End cover
Seal ring
Seal ring
Commutator
ring
Commutator
Manifold
30- 194-6
0
8. Rotor set
8A. Rotor
8B. Stator half
8C. Vane
8D. Stator half
8E. Vane
9. Wear plate
10. Drive link
11. Thrust bearing
12. Coupling shaft
12A. Key
128. Nut
12C. Washer
12D. Bolt
12E. Lock washer
12F. Retaining ring
13.
14.
15.
16.
17.
18.
19.
20.
21.
Bearing (inside)
Thrust washer
Thrust bearing
Seal
Backup washer
Housing
Bearing (outside)
Seal
Backup washer
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
*
*
Replace all seals and bearings with new parts.

Wash all parts with a petroleum-based
solvent,
then blow with air to dry.
1.
Press fit outside bearing (19) to housing (18).

*
Press-fitting depth (from flange surface):
7.37 - 7.87 mm
&
Bearing : Grease (G2-LI)
2.
Press fit seal (20) to housing (18).

*
Press-fitting depth (from end face of flange):
0.5 mm
3.
Install
backup
washers
MOTOR
(17) and (211, and seal
(16).
*
Install seal (16) with the lip at the top (the
inside of the motor).
Inset-t thrust
washers
(14)
(15).
*
Install so that washers
both sides.
5.
and thrust
bearing
hold the bearing
on
Press fit inside bearing (13) to housing (18).

+
Press-fitting depth (from flange surface) :
2.67 - 3.18 mm
=,
DWG00287
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
6.
Install coupling shaft (12).

*
To prevent damage to the seal, wind masking tape around the key groove before installing.
.
Grip housing (18) in a vice.
.
If the assembly is made correctly, the coupling shaft will be approx. 2.5 mm lower
than the mounting
surface of the housing
wear plate.
7.
Insert thrust bearing (II),

(4) to housing (18).
6
Seal ring : Grease
8.
and install
seal ring
(G2-LI)
Install drive link (IO), then put wear

it.
plate (9) on
9. Install seal ring (4) to rotor set (8), then put wear
plate (9) on it.
*
Install with the seal ring side at the bottom.
*
Replace seal ring (4) between stators (8B)
and (8D) of the rotor set with a new part.
&
Bearing : Grease (G2-LI)
30-194-8
0
MOTOR
DISASSEMBLY
10. Install
(7).
&
CIRCLE ROTATION
AND ASSEMBLY
seal ring (4) in seal groove

Seal ring : Grease
MOTOR
of manifold
(G2-LI)
11. Put manifold (7) on rotor set (8).

Ir Be careful to install the manifold the right
way up. (Set it so that the oil passage hole
with the large diameter pitch is at the bottom (rotor set side).)
12. After installing seal ring (4) in seal groove

manifold (71, install commutator
ring (6).
I II
---lJ---
I\
DWG00296
of
_=;i=;_
1 DWG00297
13. Install seal ring (3) to commutator

(5), then install so that head of drive link enters hole in
center of commutator.
DWG00298
30-194-9
0
DISASSEMBLY
AND ASSEMBLY
14. Install seal ring (4) in seal groove

(2).
&
Bearing
CIRCLE ROTATION
of end cover
MOTOR
: Grease (G2-LI)
15. Put end cover (2) on commutator

ring (6), and
install bolts (I).
m
Bolt : 67.7 + 6.9 Nm IS.90 + 0.70 kgm1
Bolt tightening order
DWG00300
16. Install shaft key (12A), bolt (12D), washers (12E)

and (12C), and retaining ring (12F).
*
Check the direction of rotation of the motor.
Direction of rotation of motor (seen from
output shaft side)
When pressure oil is applied to port A:
Counterclockwise
When pressure oil is applied to port B:
Clockwise
(Thread size of ports A and B: 518 - 14UNF)
B port
/
30-194-10
0
DWG00278
REMOVAL OF DRAWBAR
SHIFT CYLINDER,
BLADE LIFT CYLINDER,
LIFTER GUIDE
A
A
Lower work equipment

Stop
the
times
the remaining
engine.
completely
Operate
to the ground.
control
pressure
lever
from
several
the hydraulic
piping.
1.
Drawbar
shift cylinder
Disconnect
2.
hoses
(2)
cylinder
(1) and remove
kg
C?YI
Drawbar
Blade
lift cylinder
I)
Temporarily
connect
and
and
(3)
from
drawbar
shift cylinder:
72 kg
sling blade lift cylinder
(41, then dis-
hoses (5) and (6) from blade lift cylinder
remove
cylinder
head
end
from
joint (7).
2)
shift
it.
Loosen bolt (81, and remove
holder (9).
drawbar
3) Remove blade lift cylinder assemblv (1 1) from

lifter guide (10).
kg
tT?z
3.
Upper
1)
lifter
Blade lift cylinder assembly: 158 kg
guide
Sling upper lifter guide (101, then remove nut

(12) and bolt (13).
Upper lifter guide: 96 kg
2)
4.
P2350
F424
P2350
i 425
P2350
I427
Sling and remove upper lifter guide (10).
Lower
lifter
guide
1) Sling lower lifter guide (14). Loosen bolt (15)

and pull out bank control pin assembly (16).
A
m
2)
Lower lifter guide: 550 kg
Sling lower lifter guide (14) and lower.
INSTALLATION
OF DRAWBAR
SHIFT CYLINDER,
BLADE LIFT CYLINDER,
LIFTER GUIDE
1.
Lower lifter guide

1)
Sling
lower
lifter
guide
(14)
guide hole 1s and main frame
& kg
2)
2.
Lower lifter guide:
and
lift
up align
hole 8.
550
install bank control pin assembly
kg
(16).
Upper lifter guide

Sling
upper
tighten
kg
C!z!
*
w
lifter
guide
(lo),
insert
shim
(17)
and
bolt (13) and nut (12).

Upper
Standard
lift guide:
96 kg
shim thickness:
Mounting
2.0 mm
bolts: 539.4 & 49.0 Nm (55 k 5 kgm)
P2350
I425
P2350
I430
3.
Blade lift cylinder

1) Temporarily sling blade lift cylinder (4) and insert
in upper lifter guide hole.
kg
&?I
4.
Blade lift cylinder: 158 kg
2)
Fix with holder (9) and bolt (8).
3)
Install blade lift cylinder head side to drawbar ball

joint (7) and connect hoses (5) and (6).
Drawbar shift cylinder

Install drawbar shift cylinder (1) head side to lifter
guide ball joint (18).
Install bottom side to drawbar ball joint (191, and connect hoses (2) and (3).
& kg
Drawbar shift cylinder: 72 kg
REMOVAL OF ARTICULATE
ASSEMBLY
1.
Disconnect
remove
head
greasing
tube
(1) from
CYLINDER
pin
(2), then
bolt (3) and pin (2).
If it is difficult
sidual
nut
to remove
pressure
of hoses
the
pin
in the cylinder,
(4) and
because
loosen
of re-
the sleeve
(5) to discharge
the
resid-
ual pressure.
2.
Disconnect
hoses (4) and (5) from
3.
Sling articulate
4.
Remove
5.
Sling and remove
cylinder
cylinder.
assembly
(6).
bolt (9) and pin (8).
Articulate
articulate
cylinder
assembly
cylinder
assembly:
72 kg
(6).
INSTALLATION OF ARTICULATE
CYLINDER ASSEMBLY
1.
Sling
articulate
to mounting
it with
2.
3.
Start
(6) and set bottom
then
insert
pin
(8) and
fix
hoses (4) and (5) to cylinder.
Install
hoses without
engine
rod
assembly
(IO),
lock plate (11) and bolt (9).
Connect
*
cylinder
bracket
and
connecting
insert
pin
twisting
extend
pin
cylinder
holes
(2) and fix
and interference.
with
it with
rod,
holes
lock
align
piston
in bracket
plate
(12),
(13) and
bolt
(3).
4.
Connect
*
grease
tube (1) to pin (2).
Operate
the
control
cylinder
then
add
tank to the specified
lever
engine
to
oil
circulate
into
the
oil
in the
hydraulic
level.
30?A99
REMOVAL OF REAR MOUNT

RIPPER CYLINDER ASSEMBLY
completely
1.
Sling cylinder assembly
(I 1.
2.
Remove
to the ground.
lock plate (2) at head end and remove
If it is difficult
residual
sleeve
to remove
pressure
in
the
the
pin (3).
pin because
cylinder,
nut of the hose to discharge
loosen
of
the
the residual
pressure.
3.
Disconnect
cylinder
bottom
hose
(4)
assembly
(1).
and
cylinder
head hose (5) from cylinder.

4.
Remove
5.
Sling and remove

&
support
Rear
(6).
cylinder
mount
ripper
cylinder
assembly:
130
kg
INSTALLATION
OF REAR
MOUNT RIPPER CYLINDER
ASSEMBLY
1.
Sling
cylinder
mounting
assembly
(11, and set bottom
hole to
bracket.
2.
Install support
3.
Connect
(6).
cylinder
head hose (5) and cylinder
bottom
hose (4).
*
4.
Start
Install hoses without

engine
and fully
rod hole and bracket

5.
6.
twisting.
extend
cylinder.
Align
piston
hole.
Install head pin (13) and fix with lock plate (2).
Operate
through
the
control
lever
to
circulate
engine
oil
in cylinder. Then add engine oil into hydraulic
tank to be specified
30200
level.
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
023502
Serial No.: 11001 12502
30-201
(6)
3. Piston and head assembly

1) Set piston rod assembly (6) to tool A1.
2) Using tool A3, remove nut (7).
Cylinder
Steering
Leaning
Width across flats

of nut
46 mm
50 mm (*1)
60 mm (*2)
Blade shift
70 mm
Blade lift
70 mm
Drawbar shift
70 mm
Articulate
75 mm
Power tilt
75 mm
Ripper
80 mm
(*1) Serial No.: 11001 12050

4. Disassembly of piston assembly

Remove piston ring (11) and water ring (12)
from piston (8).
5. Disassembly of head assembly
1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust
seal (15).
3) Remove rod packing (16).
4) Remove bushing (17).
30-202
(6)
023502
3) Remove piston (8) and slider (9).

a Slider (9) is installed to the steering cylinder only.
4) Remove cylinder head assembly (10).
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
023502
Serial No.: 11001 12502
30-203
(6)
Cylinder
Steering
Width across
flats of nut
46 mm
50 mm (*1)
Leaning
60 mm (*2)
Blade shift
Blade lift
70 mm
Drawbar shift
Articulate
75 mm
Power tilt
Ripper
80 mm
(*1) Serial No.: 11001 12050

30-204
(6)
Nm
{kgm}
785 78.5
{80 8}
1,080 110
{110 11}
1,770 177
{180 18}
2,600 260
{265 26.5}
3,330 333
{340 34}
2,600 260
{265 26.5}
3,140 314
{320 32}
2,840 284
{290 29}
3970 397
{405 40.5}
023502
3. Piston, head assembly

1) Set piston rod to tool A1.
2) Assemble cylinder head (10) to piston rod.
3) Fit slider (9) and install piston assembly (8),
then using tool A3, tighten nut (7).
a Wash and remove all grease and oil
from the thread of the piston rod where
the nylon nut is fitted.
2 Rod thread:
Thread tightener (Loctite #262)
3 Piston nut
023502
30-205
(6)
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
a The symbols used in the special tools and illustrations indicate the following cylinders.
Cylinder
1. Set cylinder assemble (1) to tool A1.
Cylinder symbol
ST
LE
BS
BL
DS
AR
PT
RP
Steering
Leaning
Blade shift
Blade lift
Drawbar shift
Articulate
Power tilt
Ripper
Special tools
Parts No.
790-502-1003
1 790-502-2000
790-101-1102
2 790-330-1100
790-302-1290
790-102-1320
3
790-102-1330
790-302-1340
790-201-1702
790-101-5021
01010-50816
790-201-1741
4
790-201-1761
790-201-1781
790-201-1791
790-201-1811
790-201-1500
A
790-101-5021
01010-50816
790-201-1550
5
790-201-1570
790-201-1590
790-201-1610
790-201-1620
6 790-702-1000
796-720-1630
07281-00709
796-720-1650
07281-01019
796-720-1650
7
07281-01159
796-720-1670
07281-01279
796-720-1680
07281-01589
30-205-1
(6)
Part Name
Qty
Repair stand
Repair stand
Pump
Wrench
Socket (60 mm)
Socket (70 mm)
Socket (75 mm)
Socket (80 mm)
Push tool KIT
Grip
Bolt
Push tool
Push tool
Push tool
Push tool
Push tool
Push tool KIT
Grip
Bolt
Plate
Plate
Plate
Plate
Plate
Expander
Ring
Clamp
Ring
Clamp
Ring
Clamp
Ring
Clamp
Ring
Clamp
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
LE
BL, BS, DS
PT, AR
RP
ST
LE
DS
BL, BS, PT, AR
RP
ST
LE
DS
BL, BS, PT, AR
RP
ST
LE
BL, BS, DS
PT, AR
RP
023502
Symbol
2. Cylinder head assembly

Power tilt, Blade lift, Drawbar shift, Articulate,
Ripper cylinder
1) Remove cylinder head bolt.
2) Disconnect cylinder head assembly (2) from
the cylinder.
Cylinder

Using tool A2, loosen cylinder head assembly
(4) and disconnect from the cylinder.
a Do not loosen bolt (18) but disconnect plate
(19), collar (20) and cylinder head (4) as an
assembly.
Width across flats of

mounting bolt
22 mm
24 mm
27 mm
023502
Blade lift, Drawbar shift

Power tilt, Articulate
Ripper
Steering, leaning cylinder

1) Raise rotation stopper.
2) Using tool A2, disconnect cylinder head
assembly (4) from the cylinder.
30-205-2
(6)
4. Piston and head assembly

1) Set piston rod assembly (5) to tool A1.
2) Using tool A3, remove nut (7).
Cylinder
Steering
Leaning
Blade shift
Blade lift
Drawbar shift
Articulate
Power tilt
Ripper
Width across flats of

mounting bolt
46 mm
60 mm
70 mm
70 mm
70 mm
75 mm
75 mm
80 mm
3) Remove piston (8) and slider (9).

4) Remove cylinder head assembly (10).
30-205-3
(6)
023502
3. Piston rod assembly

Pull out piston rod assembly (5).
a Put a container under the cylinder to catch
the oil.
5. Disassembly of piston assembly

Remove piston ring (11) and wear ring (12) from
piston (8).

1) Remove bolts (18) (width across flats: 13
mm) to remove plate (19) and collar (20).
2) Remove ring (21) and dust seal (22) from
collar (20).
3) Remove O-ring, backup ring (13) and O-ring
(23).
4) Remove dust seal (15) and rod packing
(16).
023502
6. Disassembly of head assembly

Steering, Leaning, Blade lift, Drawbar shift,
Articulate, Power tilt, Ripper cylinder
1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust
seat (15).
3) Remove rod packing (16).
30-205-4
(6)
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
2) Using tool A5, assemble dust seal (15).

a The symbols used in the illustrations indicate
the following cylinders.
Cylinder
Steering
Leaning
Blade shift
Blade lift
Drawbar shift
Articulate
Power tilt
Ripper
Cylinder symbol
ST
LE
BS
BL
DS
AR
PT
RP
a Be careful not to damage the packings, dust

seals, and O-rings when assembling.
3) Install snap ring (14) to dust seal (15).

4) Install rod packing (16), then install O-ring
and backup ring (13).
a Do not try to force the backup ring into
position. Warm it in warm water (50
60C) before fitting it.
30-205-5
(6)
023502
1. Assembly of head assembly

Cylinders other than blade shift cylinder
1) Using tool A4, press fit bushing (17) to head
(10).

1) Using tool A4, press fit bushing (17) to head
(10).
2) Using tool A5, assemble dust seal (15).
a Take care of the installed direction of the
dust seal.
4) Install wear ring (12).
023502
3) Install rod packing (16), O-ring (23), O-ring

and backup ring (13).
rod packing.
a Do not try to force the backup ring into
position. Warm it in warm water (50
60C) before fitting it.
2. Assembly of piston assembly

1) Using tool A6, expand piston ring (11).
a Set the piston ring on the expander and
turn the handle 8 10 times to expand
the ring.
2) Remove piston ring (11) from tool A6, and
install to piston (8).
3) Using tool A7, retract piston ring (11).
4) Set dust seal (22) and ring (21) to collar (20)

and install them to head (10).
dust seal.
5) Install plate (19) and tighten bolts (18).
30-205-6
(6)
3. Piston, head assembly

1) Set piston rod (5) to tool A1.
2) Assemble cylinder head (10) to piston rod.
3) Fit slider (9) and install piston assembly (8),
then using tool A3, tighten nut (7).
a Wash and remove all grease and oil
from the thread of the piston rod where
the nylon nut is fitted.
2 Rod thread:
Thread tightener (Loctite #262)
3 Piston nut
Cylinder
Width across
flats of nut
Steering
46 mm
Leaning
60 mm
Blade shift
Blade lift
70 mm
Drawbar shift
Articulate
75 mm
Power tilt
80 mm
4. Piston rod assembly

Steering, blade shift, leaning cylinder.
1) Set cylinder to tool A1.
2) Assemble piston rod assembly (5) to cylinder.
023502
Ripper
Nm
{kgm)
785 78.5
{80 8}
1,770 177
{180 18}
2,600 260
{265 26.5}
3,330 333
{340 34}
2,600 260
{265 26.5}
3,140 314
{320 32}
2,840 284
{290 29}
3,970 397
{405 40.5}
3) Using tool A2, install cylinder head (4).

3 Cylinder head
Cylinder
Steering
Blade shift
Leaning
Nm {kgm}
441 44.1 {45 4.5}
785 78.5 {80 8}
677 67.6 {69 6.9}
4) Caulk rotation stopper to cylinder.

a Steering and leaning cylinder only.
30-205-7
(6)
Power tilt, ripper, blade lift, drawbar shift, articulate cylinder.

1) Set cylinder to tool A1.
2) Assemble piston rod assembly (5) to cylinder.
023502
5. Remove cylinder assembly (1) from tool A.
3) Assemble cylinder head (2) to cylinder, then

tighten with a torque wrench.
3 Cylinder head mounting bolt
Cylinder
Width across
flats
Blade lift
22 mm
177 19.6
{18 2}
24 mm
278 32.3
{28.3 3.3}
27 mm
385 42.1
{39.3 4.3}
Drawbar shift
Power tilt
Articulate
Ripper
Nm
{kgm}
30-205-8
(6)
REMOVAL OF CIRCLE ROTATION GEAR AND

HYDRAULIC OIL MOTOR ASSEMBLY
Serial No.: 11001 - 12050
Lower
the work
Disconnect
cable
equipment
from
to the grond.
negative
(-)
terminal
of bat-
tery.
Loosen
I
drain
plug (1) and drain
Hydraulic
tank:
hydraulic
oil.
108 P
235FO2244
Remove
4.
hoses
Remove
mount
bottom
+
5.
bolt
(8), and
tap
dowel
pin
(9) from
to remove.
Dowel
pin: 2 places
Using
eyebolts
mm),
sling
assembly
*
(2), (3), (41, (5), (6), and (7).
(Thread
circle
dia.
rotation
(IO), and remove
For details
gear
ROTATION
12 mm,
and
Pitch
hydraulic
gear assembly
of disassembling
assembly
CIRCLE
gear
(II),
see
GEAR,
1.75
motor
(11).
the clutch
portion
of
DISASSEMBLY
HYDRAULIC
OF
MOTOR
ASSEMBLY.
6 kg
Circle rotation
gear, hydraulic
motor
assembly:
17
235CDO2107
262 kg
1
6.
Remove
semf$y
circle
rotation
gear
and
hydraulic
motor
as-
(IO).
235FO227t
30-206
0
INSTALLATION OF CIRCLE ROTATION

HYDRAULIC OIL MOTOR ASSEMBLY
GEAR AND
Serial No.: 11001 - 12050

1.
Using
eyebolts,
draulic
motor
and install
f
For
gear assembly
(11).
details
of assembly
(II),
TATION
Align
circle
(IO),
assembly
2.
raise
assembly
see
rotation
then
and
dowel
pin (9) with
on
and
hy-
drawbar,
adjustment
ASSEMBLY
GEAR, HYDRAULIC
gear
set
of gear
OF CIRCLE
RO-
MOTOR ASSEMBLY.
pin hole,
and tighten
mount
bolt (8).
3.
Connect
hoses (2), (3), (4), (5), (6), and (7).
235COO2106
4.
5.
Tighten
drain
plug
(1) and
oil filler
(12) to specified
Hydraulic
tank:
cable to negative
the
Run
engine
to
hydraulic
oil through
108 li
Connect
system.
add
level.
(-)
terminal
circulate
the
of battery.
oil through
the
235CDO2107
235FO2244
30-207
0
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
GEAR, HYDRAULIC
MOTOR
REMOVAL OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
a
Lower the work

ground.
equipment
1.
Remove
tery.
2.
Loosen drain plug (I) and drain hydraulic

A
&
Hydraulic tank : 108 e
3.
Remove
hoses (2) and (3).
4.
Remove
mount
cable from negative
completely
to the
4-J terminal
of bat-
oil.
bolts (4).
II
5.
DWG00248
Using eyebolts (Thread = 20 mm, Pitch = 2.5 mm),

lift off circle rotation gear and hydraulic motor
assembly (5).
& kg
Circle rotation gear, hydraulic

sembly : 345 kg
motor as-
DWG00249
30-207-l
0
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
GEAR, HYDRAULIC
MOTOR
INSTALLATION OF CIRCLE
MOTOR ASSEMBLY
1. Using eyebolts,
motor
hydraulic
bar.
gear and
raise circle rotation
assembly (5) and install to draw-
DWG00249
Mount
bolts
(4) :
549 + 59 Nm I56 t 6 kgm}
2.
Connect
hoses
DWG00248
(2) and (3).
drain plug
Tighten
filler (6) to specified
Hydraulic
(I) and
level.
tank
add
oil through
DWG00247
oil
: 108 e
of battery.
(-1 terminal
Connect negative
the oil through
Run the engine to circulate
*
the system. Then check the oil level again.
30-207-2
0
DISASSEMBLY
OF CIRCLE ROTATION
HYDRAULIC
OIL MOTOR ASSEMBLY
Serial
1.
No.:
11001
Draining
1)
- 12050
oil
Remove plug (I) and drain oil

_ :
2)
Circle rotation gear: Approx.
16 II
Remove plug (2) and drain oil

_ :
2.
Circle
Clutch:
rotation
Remove
gear
Approx.
180 mQ
- hydraulic
bolt (3) and dismount
sembly (5) from circle rotation
oil motor
assembly
hydraulic oil motor asgear assembly (4).

I
3.
GEAR AND
9A
235FO2277
Key
Remove key (6) from hydraulic oil motor assembly
P2350
4.
Clutch
1)
2)
3)
Remove cover (9A).

Loosen locknut (7) and remove bolt (8).
Remove cover (9).
4)
Remove washer
order.
30-208
0
(1 O), spring (1 I), piston (12) in
1483
z
z
4)
Remove
*
5.
Reverse
1)
Disc:
discs
(13) and plates
6 PCS, plate:
(14) in order.
5 PCS.
gear (with dry clutch)
Loosen
shim
bolt
(18A).
(18E), springs
then
remove
(18F), end
plate
cover
(18C),
(18G),
plates
(18H), and discs (18J).

2)
Loosen
remove
lock
holder
plate
(18L)
(18M),
(18P), gear (18R), and collar
and
shims
bolt
(18K),
(18N),
then
coupling
(18T).
Ej
-
+ziiib
18H
18J
F235014OI
6.
Cover
Remove collar (2 1)
7.
Housing
Remove housing (22) and shim (23).
$2350
8.
Worm wheel shaft assembly

1) Remove lock plate, then remove
gear (25)
I466
from
shaft (24).
2)
9.
Remove shaft (24) and washer
(26) from case.
Worm gear . Bearing assembly

1)
Remove
worm
gear
- bearing
assembly
from
case.
2)
Remove
bearing (28) from shaft (27).
P23503468
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
GEAR AND
HYDRAULIC
OIL MOTOR
ASSEMBLY OF CIRCLE
ROTATION GEAR AND
HYDRAULIC OIL MOTOR
ASSEMBLY
Serial
1.
No.: 11001 - 12050
Worm gear . bearing assembly

1) Using press-fit tool ($1751, press fit bearing
(28) on shaft (27).
P2350
2)
Inset-t worm
into case.
gear
. bearing
assembly
I468
(29)
P2350 9 469
2.

1) Using push tool kit (o98), press fit bearing
(31) to case (30).
2) Using push tool kit (o115), press fit oil seal
(32).
&
&
3)
3.
Oil seal lip: Grease (G2-LI)

Outside circumference
of oil seal:
Gasket sealant (LG-I)
Install gear (18) to shaft (17) and fix it with a
lock plate.
Sr Bend lock plate securely.
Ir Insert washer (26) at the upper and lower
ends of the shaft securely.
DEG00023
Housing
1) Attach shim (23) to housing (22) and install
it in case.
Sr Fix O-ring in housing.
*
Adjust rotating torque with shim.
Ir Rotating torque:
4.9 to 15.7 Nm {0.5 to 1.6 kgm)
&
O-ring groove: Grease (G2-LI)
P23501470
30-211
0
DISASSEMBLY
4.
AND ASSEMBLY
CIRCLE ROTATION
Reverse gear (with drv clutch)

1) Fit O-ring (18% to dollar (18T) and gear (18R),
then install to shaft (24).
&
Rotating portion: Lubricant (LC-G)
6
2) Fit O-ring (180) to coupling (18P), then install to shaft (24).
6
Spline portion of shaft and coupling
(18P): Lubricant (LM-PI
3) Insert plates (18H) and discs (18L) between
gear (18R) and coupling (18P).
&
Spline portion of gear (18R):
Lubricant (LM-P)
4) Install shims (18N), holder (18M), and lock
plate (18L) to shaft with bolt (18K).
*
Adjust so that clearance A of the shim is
1 mm.
5) Assemble end plate (18G) and springs (18F),
then install shims (18E) and collar (18C) with
bolt (18A).
GEAR AND
HYDRAULIC
OIL MOTOR
DEG00024
.lUJ
F23501409
F235014
30-212
0
DISASSEMBLY
5.
6.
AND ASSEMBLY
CIRCLE ROTATION
Cover
Using push tool kit (o95), press fit bushing
to cover (21), then install to case.
Ir Install an O-ring to the cover.
6
i
(33)
Clutch
1) Press fit oil seal (34).
2)
Insert plate (17) and snap ring (16) to housing (15).

t
Install an O-ring to the housing.
3)
Install discs (13) and plates (14) in turn.

+
Discs: 6 PCS.
*
Plates: 5 pcs.
$
i:
Q
$
8
$
GEAR AND
HYDRAULIC
OIL MOTOR
DISASSEMBLY
4)
5)
6)
7)
AND ASSEMBLY
CIRCLE ROTATION
GEAR AND
HYDRAULIC
OIL MOTOR
Install piston (12).

Ir Install an O-ring to the piston.
Install spring (II) and washer (IO).
Install cover (9).

Install bolt (8) and locknut (7), loosen l-1/4
turns after tightening, then lock with locknut.
*
Adjust the load on the clutch as follows.
(with
a) Loosen bolt (8) completely
spring (11) not compressed).
b) Tighten bolt (8) to compress spring
(II).
w
c)
Bolt:
56.9 2 4.9 Nm t5.8 + 0.5 kgml
Turn bolt (8) back l/6 turns, then
tighten locknut (7).
F23501326
8)
7.
Remove every second mounting

bolt (remove 3 bolts, one from each pair) of cover
(9), then install cover (9A), and tighten with
bolts that were removed.
Key
Install
key (6) to hydraulic
oil motor
assembly
(5).
P2350
30-214
0
1483
z
%
g
DISASSEMBLY AND ASSEMBLY
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
8. Circle rotation gear, hydraulic oil motor assembly

Align circle rotation gear assembly (4) and hydraulic oil motor assembly, then tighten with
bolts (3).
9. Refilling with oil
1) Tighten drain plug (1), then add gear oil to
the specified level.
5
Circle rotation gear case:

Approx. 16 (GO90)
2) Tighten drain plug (2), then add engine oil

to the specified level.
Clutch: Approx. 180 m (EO30)
023502
30-214-1
(6)
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
GEAR, HYDRAULIC
MOTOR
DISASSEMBLY OF CIRCLE
MOTOR ASSEMBLY
1.
Draining oil
I) Remove drain plug (I) and drain oil.
2)
Remove
-
Upper case: Approx.
9.8 Q
drain plug (2) and drain oil.

Lower case: Approx.
0.2 k?
2.
Hydraulic motor assembly

Remove 4 bolts (31, then remove motor 14).
Ir Be careful not to drop key (41) fitted to the
shaft of the motor.
3.
Clutch
1) Remove 8 bolts (61, then remove cover (7).
2) Remove 3 bolts (8), then remove holder (9)
and shims (IO).
*
Check the number and thickness of the
shims, and keep in a safe place.
spring (12), and plate
3) Remove collar (II),
4)
(13).
Remove clutch discs (14) and plates (15) in
order, then remove washer (16).
Clutch disc (14) : 11
Clutch plate (15) : 10
30-214-2
0
DWG00250
DISASSEMBLY
AND ASSEMBLY
4.
Housing
Remove nut (171, then remove housing (18).
Ir Check the number and thickness of shims
(191, and keep in a safe place.
5.
Worm wheel
Install eyebolts (Thread = 6 mm, Pitch = 1 mm) to
worm wheel (20), then remove worm wheel.
Ir The % mark in the diagram shows the eyebolt
hole.
CIRCLE ROTATION
GEAR, HYDRAULIC
MOTOR
OWC
Worm gear, bearing assembly

I) Remove worm gear and bearing assembly
from case (5).
2) Remove bearing (22) from worm shaft (21).
7.
Pinion gear
1) Remove 8 bolts (231, then remove cover (24).
23
24
DWG00256
30-214-3
DISASSEMBLY
2)
3)
CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
AND ASSEMBLY
Extend lock plate (251, remove bolt (26), then

remove
holder (27).
*
Check the number
and thickness
of the
shims under the lock plate, and keep in
a safe place.
Remove
4 bolts (291, then remove
housing
(30).
DWG00257
4)
Pull out bushing
(31) from
housing
(30).
I
5)
Remove collar (321, then remove pinion

(33) and washer (34).
Ir
Be careful
not to damage
floating
DWG00258
gear
seal
(35).
8.
Worm wheel shaft

1)
2)
Remove worm wheel shaft (36), then remove

washer (37).
Pull out bushing
(38) from case (5).
33
32
30-214-4
0
DWGO
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
GEAR, HYDRAULIC
MOTOR
ASSEMBLY OF CIRCLE
MOTOR ASSEMBLY
Serial
1.
No.: 12051 and up
Worm gear, bearing assembly

I) Press fit bearing (22) to worm gear (211, and
insert worm gear (21) to case (5).
2)
3)
Install housing (18) to case (5).

.
Install an O-ring to the housing.
O-ring : Grease (G2-LI)
&
.
Insert the same thickness of shim (19)
that was removed during disassembly.
To apply preload to bearing, add suitable
thickness of shim (19) so that rotating torque
of worm gear (21) is 4.9 - 9.8 Nm iO.5 - 1.0
kgm1
2.

Press fit bushing (38) in case (5).
I)
2) Pass washer (37) over shaft (36), and insert
in case (5).
.
P portion
Install so that the chamfered
of washer (37) is at the top.
3.
Pinion gear
I) Press fit bushing
(31) to housing
(30).
30-214-5
0
DISASSEMBLY
2)
AND ASSEMBLY
Adjust shim at pinion gear portion.

* With floating seal (35) removed, assemble pinion gear portion completely,
and
adjust clearance
between
washer (34)
and pinion gear (33).
i) Install washer (34) and pinion gear (33).
Sr Insert three 0.2 mm clearance gauges
between washer (34) and pinion gear
(33) from 3 directions, and install in
this condition. (In order to maintain
0.2 mm clearance)
ii) Install collar (321, insert shims (28), then
install holder (26).
.
Types (thickness) of shim (28):
235-70-15860:
1 .O mm
235-70-I 5870: 0.5 mm
235-70-15880:
0.2 mm
iii) Install housing (30).
iv) Adjust clearance
between
washer (34)
and pinion gear (33) with shim.
Clearance: 0.2 mm
VI After adjusting, remove all parts installed
in Steps i) - iii).
CIRCLE ROTATION
GEAR, HYDRAULIC
is
25
MOTOR
DWG00261
3)
Using tool B, install floating seal (35) to case

(5), pinion gear (331, and housing (30).
*
Remove all oil and grease from the Oring and the O-ring contact surface.
Ir There must be no dirt stuck to the mating surface (sliding surface) of the floating seal.
DWG00262
30-214-6
0
DISASSEMBLY
4)
5)
6)
7)
AND ASSEMBLY
CIRCLE ROTATION
GEAR, HYDRAULIC
Install washer (34) and pinion gear (33) to

shaft (36).
Install collar (321, insert shim (281, then install holder (26).
Ir Insert the thickness of shim adjusted in
Step 2) iv).
+ After tightening bolt (261, secure the bolt
with lock plate (25).
Install housing (30).
Install cover (24) to housing (30).
*
Fit the O-ring in the O-ring groove of the
housing.
&
MOTOR
DWG00256
33
32
28
30
29
4.
is
25
DWG00261
Worm wheel
Fit eyebolt to worm wheel (201, and install to
shaft (36).
*
Remove the housing of the worm gear. Mesh
it with the worm gear, then install the worm
gear housing again.
DWG00254
5.
Clutch
1) Insert washer (16) in worm wheel, then insert discs (14) and plates (15) in order.
Discs (14): 11
Plates (15): 10
2) Install plate (II), spring (12), and collar (13).
3) Insert shim (IO) on top end of shaft (36),
then install holder (9) with bolt (8).
6.
Cover
Install cover (7) to case (5).
*
Install the O-ring to the cover.
a
30-214-7
0
DISASSEMBLY
AND ASSEMBLY
7.
Hydraulic motor assembly

install hydraulic motor (4).
Ir Install the key to the shaft of the hydraulic
motor.
8.
Refilling with oil

I)
Install drain plug (I).
2) Remove
oil filler plug (39), add a small
amount of gear oil, and check that oil comes
out from drain plug (2).
3) Install drain plug (2).
4) Remove level plug (40), then add gear oil
until oil comes out from plug.
Case : Approx.
CIRCLE ROTATION
MOTOR
10 e
30-214-8
0
GEAR, HYDRAULIC
DWG00250
REMOVAL
OF BLADE
ASSEMBLY
Serial No.: 11001 - 12050
Start
engine,
operate
work equipment
the control
(approx. 200
Set a block (approx.
780
lever to raise the
mm).
mm) under the circle to sup-
port it securely.
1. Operate
the control
lever and extend
blade side shift
cylinder piston rod (1) to pull out blade (2).

2.
3.
Loosen
bolts (3) and (4), pull out pin (5) and remove
bracket
(6).
Fully retract
piston rod (1) and sling blade (2).
Raise blade
(2) with
a crane,
slide the sling position
of the wire to the center of the blade, and dismount
kg
C!?J
Blade assembly:
INSTALLATION
ASSEMBLY
z
approx.
1540
it.
kg
OF BLADE
Serial No.: 11001 - 12050

1. Sling center of blade (2) and set to adjuster.
2.
While
extend
sliding
it reaches
a=d
the wire,
the cylinder
operate
B43,
P2350
I437
lever to
piston rod (1) and push it in until
a position where
Blade
the control
P2350
guide
rail
it can be connected.
(upper,
lower):
Grease
(G2-LI)
3.
Raise
blade
side shift
engine and operate
cylinder
the control
with
a crane,
lever to extend
start
piston
rod (1).
4.
Set cylinder
tighten
5.
rod to bracket
(6) fix with
pin (5) and
bolts (3) and (4).
Raise blade and pull out block from under the circle.
30-2 15
0
REMOVAL OF BLADE
ASSEMBLY
Serial No: 12051 and up
A
Start the engine, operate the blade lift lever to

raise the blade approx. 200 mm from the ground,
then put a stand under the circle to support it
securely.
1. Operate blade side shift lever to extend blade

side shift cylinder piston rod (I) fully and push
out blade (2).
2.
Remove 2 bolts (3), remove

out pin (5).
3.
After retracting blade side shift cylinder rod (I)

fully, raise blade (21, and move position of wire
towards center while pushing blade out to remove.
+j kg
Serial
1.
2.
: 1600 kg
Blade assembly
INSTALLATION
ASSEMBLY
plate (4), then pull
OF BLADE
No.: 12051 and up
Raise center of blade (2), and set in position on

adjuster.
Move position of wire while extending
blade
side shift cylinder rod (I) and push in to position where it is possible to connect.
&
Blade guide rail (top, bottom):
Grease
3. Lift blade side shift cylinder

engine and extend fully.
rod (I),
(G2-LI)
then
start
4.
Position cylinder rod to bracket (61, secure with

pin (5), then tighten plate (4) and bolt (3).
5.
Raise blade and remove

cle.
30-215-l
0
support from under cir-
REMOVAL
DRAWBAR
1.
2.

Remove
drawbar
and remove
3.
Remove
completely
shift
shift
(I)
bottom
cap
(2)
(3).
cylinder
from drawbar
to the ground.
cylinder
from drawbar
blade
remove
4.
OF CIRCLE AND
ASSEMBLY
(4)
head
cap
(5) and
(3).
Sling circle and drawbar
assembly
(6). loosen nut (7)
and pull out cover (8) from bolt (9).

Remove
circle
and
drawbar
assembly
from
main
frame.
+
Check the number
and thickness
of shims
(II),

Circle and drawbar
3,050
3,600
assembly:
kg (Serial
kg (Serial
No.: 11001 - 12050)

No.: 12051 and up)
INSTALLATION
OF CIRCLE
AND DRAWBAR ASSEMBLY
1.
Sling
circle
and
top ball joint
drawbar
and cover (81, and tighten

*
Install
the
same
disassembled.
.
Standard
It
assembly,
(I 0) to main frame,
number
of shims
shim thickness:
(11)
drawbar,
one shim
If too many
shims
&&
Ball joint:
as was
play in the
(11) each to adjust.
are removed,
will not move properly,

nut to come
(1 I)
2 mm (0.2t x IO)
if there is excessive
remove
drawbar
shim
nut (7).
After assembling,
Note:
2.
install
fix with
the ball joint
and this will cause the
loose.
Anti-friction
Install blade lift cylinder
compound
(LM-P)
(4) head cap (5) to drawbar
(3) with shim (I 2).

3.
Install
drawbar
30-216
0
drawbar
shift
cylinder
(3) with shim (I 3).
(1) bottom
cap
(2) to
235FO2279
DISASSEMBLY OF CIRCLE AND

DRAWBAR ASSEMBLY
Serial No.: 11001 - 12050
1.
Ball joint
Loosen
nut
(3) from
drawbar
(1) and
remove
ball
joint
(2) and
cover
top end.
P2350
/,
Circle
rotation
gear
and
hydraulic
oil
I445
motor
assembly
Remove
circle
rotation
gear
and
hydraulic
OF
CIRCLE
oil motor
assembly.
For
details,
see
REMOVAL
GEAR AND HYDRAULIC
ROTATION
OIL MOTOR ASSEMBLY.
Circle guide
1)
Loosen
nut
(6)
then separate
and
drawbar
remove
circle
guides
(5),
and circle assembly.
5
235FO2281
4.
Blade side shift cylinder

Remove
snap
ring
(7), washer
remove
blade
side
shift
juster
cylinder
(8) and
pin
(9), then
(11) from
R.H. ad-
(IO).
Blade side shift cylinder:
106 kg
P2350
t 448
30-217
0
5.
Power
I)
tilt cylinder
Remove
power
tilt cylinder
(12)
head
bolt (131,
lock plate (I 4) and pin (151, then remove

center bracket
2)
Remove
power
tilt cylinder
and cap (181, then remove
6.
(12) bottom
bolt (I 7)
it.
Power tilt cylinder:
r+
it from
(16).
83 kg
L.H. adjuster
Loosen
nuts
(20),
(21)
and
(221,
and
remove
L.H.
adjuster.
&
7.
L.H. adjuster:
60 kg
Shaft
Loosen nut (23) and pull out shaft (24).
& kg
8.
Power
Shaft:
20 kg
tilt center
Loosen bolt (25)
bracket
and remove
power tilt center
brack-
et (26).
kg
CII?T??
9.
Power tilt center bracket:
82 kg
R.H. adjuster
Loosen
nuts (27)
and (28),
and remove
(29).
& kg
R.H. adjuster:
69 kg
R.H. adjuster
ASSEMBLY
DRAWBAR
Serial
1.
OF CIRCLE AND
ASSEMBLY
No.: 11001 - 12050
R.H. adjuster
Install
R.H. adjuster
(29)
to
circle
(30)
and
tighten
nuts (27) and (28).
2.
Power
bracket
Install
2)
Insert shim (32) to cap (31) and tighten
3.
tilt center
I)
power
Standard
tilt center
bracket
(26) to circle.
shim thickness:
2.0 mm
to R.H. adjuster
and center
bolt (25).
,, .b
I:
,{
Shaft
Insert
shaft
and fix with
(24)
bracket
nut (23).
30-219
0
4.
L.H. adjuster
Install adjuster (19) to circle and shaft and fix with
nuts (201, (21) and (22).
5.
Power
tilt cylinder
Install power tilt cylinder (12) bottom end with cap

(18) and tighten bolt (17).
Install power tilt cylinder head end to center bracket
(161, fix with pin (151, then tighten bolt (13) with
lock plate (14).
6.
,, ,,, _,,
I
,,
Install blade side shift cylinder (1 1) to R.H. adjuster

and fix with pin (91, washer (8) and snap ring (7).
P2350
7.
Circle rotation
gear
and hydraulic oil motor
assembly
Install circle rotation gear and hydraulic oil motor
assembly.
For details, see INSTALLATION OF CIRCLE ROTATION
GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY.
t 448
8.
Circle guide
I)
Insert shim in circle guides (5), then temporarily assemble drawbar assembly and circle assembly
with bolts (34A), (34B) and
(340.
*
*
Length of bolts:
.
34A: 195 mm (x 4)
.
34B: 170 mm (x 12)
.
34C: 150 mm (x 2)
'35FO2282
2)
Inspection clearance of circle guide.

Ir If there is no clearance between the circle and root and tip of the teeth of the
pinion gear of the circle rotation gear
assembly, replace the guide to adjust.
a
i)
ii)
Front
Center
Rear
When raising the blade off the ground,

do not raise it higher than necessary.
Set with the blade raised off the ground.
Measure
clearance
of portion
P with
feeler gauge.
.
Standard clearance of portion P:
1.5 f 0.5 mm
iii) Measure clearances of portion P, C and

R with feeler gauge.
.
Standard clearance
F: 0 mm
C: 0.7 mm
R: 1.5 mm
orF=C=R=l
mm
F is the clearance of the guide at the front.
C is the clearance of the guide at the center.
R is the clearance of the guide at the rear.
*
If the clearance at portion P and portion
F, C and R is not the standard clearance,
carry out adjustment.
235FO2283
0-B
A-A
DDG00026
DDG00027
30-221
0
3)
Adjusting clearance of circle guide.

i) Raise blade so that drawbar and ground
are parallel, and so that dimension E at
tip of blade edge and ground surface is
approx. 90 mm.
235FO2287
ii)
Loosen bolt (I), put circle guides (21, (31,

and (4) and portion F, C and R of circle
(5) in contact,
and adjust shim (6) so
that clearance
P between
top surface of
circle and bottom
surface of drawbar
is
1.5 r 0.5 mm.
(7), tighten
pusher bolt
ii) Loosen locknut
(8) of rear circle guide (41, and move
whole of circle to rear.
*
When not using circle guide pusher
bolt (8) to move the circle, use a lever block to move it.
L
iv) Move circle to rear, and set clearance
between
tip of teeth of pinion gear (9)
and root of teeth of circle (IO) to 0 mm.
When doing this, measure
clearance
H
between
pinion gear (9) and circle (IO)
(take the measurement
as a). Adjust so
that clearance H = a + 3.9 mm.
v) Loosen locknut (121, tighten pusher bolt
(13) of front circle guide (2), maintain
clearance
H between
pinion gear (9) and
circle (IO), and set clearance
F between
circle guide (2) and circle (5) to 0 mm,
then tighten
locknut (12).
4
DEG00028
3
Ifii-
A-A
30-222
0
DOG000 30
10
!-
235FO229
vi)
Check that clearance

L between tip of
teeth of pinion gear (9) and root of teeth
of circle (IO) is 3.86 mm.
vii) Check clearance H between pinion gear
(9) and circle (IO) again, loosen locknut
(14), then tighten
pusher bolt (15) of
center circle guide (3), and set clearance
C between center circle guide (3) and
circle (5) to 0.7 mm, then tighten locknut
(14).
viii)Adiust with pusher bolt (8) so that clearante R between rear circle guide (4) and
circle (5) is 1.5 mm, then tighten locknuts
(7).
ix) Tighten
I
B-B
3
DDG00031
bolt (I) and locknuts (71, (12) and
(14).
&
x)
9.
Lubricated portion of circle guide:

Anti-friction
compound (LM-PI
Check that rotation is possible at 90
high-bank position to both left and right.
*
If thickness Tl of wear plate (15) has
reached 2 mm, replace it with a new
part.
*
If either thickness T2 or T3 of wear
plate (16) has reached 2 mm, replace
with a new part.
DDG00032
Ball joint
I)
Install ball joint (2) and cover (3) to drawbar
top end.
2)
Tighten
nut (I).
P2350t445
30-223
DISASSEMBLY
CIRCLE, DRAWBAR
AND ASSEMBLY
DISASSEMBLY OF CIRCLE,
DRAWBAR ASSEMBLY
Serial
No.: 12051 and up
1. Ball joint
Loosen bolt (I),
cover (3).
2.
3.
and remove
ball joint
(2) and
Circle rotation gear, hydraulic motor assembly

Remove circle rotation gear and hydraulic motor assembly.
OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY.
DWG00265
Circle guide
Remove 16 bolts (8) and 2 bolts (8A), then remove circle guides (51, (61, (7) and (7A), and
disconnect drawbar and circle assembly.
5
4.
DWGOO266

Remove bolt (9), lock plate (IO), and pin (II),
then remove blade side shift cylinder (13) from
adjuster (12).
&I kg
: 105 kg
DWG00267
5.
Power tilt cylinder

1) Remove bolt (151, lock plate (16), and pin
(17) at head end of power tilt cylinder (14),
and disconnect from adjuster (12).
2) Remove bolt (18) at bottom end of cylinder,
remove cap (19), then remove cylinder.
el
kg
Power tilt cylinder
: 83 kg
I
30-223-l
I?\
DWC00266
DISASSEMBLY
6.
Adjuster
Remove
I)
(22).
CIRCLE, DRAWBAR
AND ASSEMBLY
cotter
pin (20) and nuts (21) and
26
15
23
DWG00169
2)
Pull out shaft (241, then remove adjuster (12).

Adjuster
//
: 300 kg
30-223-2
0
DISASSEMBLY
CIRCLE, DRAWBAR
AND ASSEMBLY
ASSEMBLY OF CIRCLE,
DRAWBAR ASSEMBLY
1.
Adjuster
1) Insert
adjuster
Adjuster
&I kg
(12) in circle.
: 300 kg
2)
3)
2.
Insert washer
(25) and shims (26) in clearance between circle and adjuster,
and adjust
clearance.
Clearance.(left,
right): 0.5 - 1.0 mm each
*
Insert washer
(25) and shims (26) uniformly
on left and right.
*
Coat the contact surface of the shim and
the circle with LM-P.
Thickness
of Washer: 3 mm
Thickness
of Shim (2 types):
0.5 mm, 1.0 mm
Pass shaft (24) through,
then install washer
(231, nuts (21) and (221, and cotter pin (20).
Power tilt cylinder

1) Secure bottom end of power
with cap (19) and bolt (18).
2)
tilt cylinder
DWGOO270
DWG00269
(14)
Power tilt cylinder

: 83 kg
&
lni:all
head end to adjuster
with pin (17),
and secure with lock plate (16) and bolt (15).
DWG00266

Install bottom
end of blade side shift cylinder
(13) to right side of adjuster
(12) with pin (II),
then secure with lock plate (IO) and bolt (9).
& kg
Blade
side shift
cylinder
: 105 kg
Circle rotation gear, hydraulic motor assembly

Install circle rotation
gear and hydraulic
motor
assembly
to drawbar.
OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY.
30-223-3
0
OWG00267
DISASSEMBLY AND ASSEMBLY
CIRCLE, DRAWBAR
023502
5. Circle guide
1) Set wear plate (28), put circle assembly on
drawbar, lay out shims (29), then temporarily tighten guides (5), (6), (7) and (7A) with
bolts.
Lay out 2 wear plates (28) each.
Install wear plate (27) to each circle
guide.
Standard shim thickness : 5.5 mm
Bolt length
(8) : 175 mm (16 bolts)
(8A) for circle guide (7A): 155 mm (2
bolts)
6. Adjusting clearance of circle guide

1) Adjusting top and bottom clearances between circle and wear plate
i) Loosen all mounting bolts, expand each
circle guide towards outside, then make
sideways clearance between wear plate
and circle 0 mm.
ii) Adjust thickness of shims (29) to adjust
clearance P in vertical direction of wear
plate (27) and circle.
Adjust for all circle guides.
Measure the clearance with the wear
plate pushed tightly against the circle guide.
Clearance P: 1.5 0.5 mm
2) Adjusting clearance from circle rotation gear
case
i) Loosen locknut (30) and pull in pushing
bolt (31). (For front, center, and rear circle guides)
ii) Loosen all mounting bolts, and move circle towards rear.
iii) Push front circle guide (5) to front with
pushing bolt (31) so that clearance H between circle (33) and circle rotation gear
case (32) is specified value.
Clearance H: 20 21 mm
iv) Tighten bolt to hold front circle guide (5)
in position.
Clearance F: 0 mm
30-223-4
(6)
DISASSEMBLY
3)
CIRCLE, DRAWBAR
AND ASSEMBLY
Adjust clearance between circle and

guide (center, rear)
i) Set clearance
F to 0 mm, then
clearance C between circle and
circle guide (6), and tighten bolt
hold in position.
Clearance C: 0.7 mm
circle
adjust
center
(8) to
3d
3i
29
27
28
DWG00275
B-B
ii)
Set clearance
F to 0 mm, then adjust
clearance R between circle and rear circle guides (7) and (7A), and tighten bolts
(8) and (8A) to hold in position.
Clearance R: 1.5 mm
8 (8A)
7(7A)
31
30
2i
c-c
7.
DWG002:6
bWG00265
Ball joint
Install ball joint (2) and cover (3) to drawbar,
and tighten bolt (I).
w
Bolt : 534.5 + 73.5 Nm I54.50 2 7.50 kgml
30-223-5
0
REMOVAL OF REAR MOUNT

ASSEMBLY
Lower the work equipment
1.
Set stand
@ (height:
completely
approx.
800
RIPPER
to the ground.
mm) under body
(I).
2.
Raise shank
remove
(2) with
a crane,
pull out pin (3). then
shank (2).
3.
Disconnect
hoses (5) and (6) from cylinder
4.
Raise body
(lj,
(4).
pull out pin (71, then disconnect
rod
(8).
5.
Hold rod (9) with jack, pull out pin (IO),
then discon-
nect link (1 I).

6.
Lift off body.

Sr
Rod (81, link (I I),
and cylinder
to the body.
kg
CE?l
7.
Lift off bracket
& kg
8.
Body:
Bracket:
1390 kg
(12) with a crane.

241 kg
Pull out pin (131, and remove
30-224
0
rod (9).
(4) are attached
INSTALLATION
OF REAR MOUNT
RIPPER ASSEMBLY
1.
Hold rod (9) with jack, and knock in pin (I 3).
2.
Raise bracket
3.
(I 2) and install.
Raise body (1). align pin hole of bracket,
link (1 1) and
rod (9). then knock in pin (I 0).

4.
Align pin holes of rod (8) and bracket,
then knock
in
pin (7).
5.
Set stand
@ under body
(11, raise shank
(2) with
down,
it
crane, align pin holes, then knock in pin (3).

*
If the
will
center
hit the
shank
work
is installed
equipment
upside
cylinder
and
may
break, so be sure never to install it upside down.

6.
Connect
*
hoses (5) and (6) to cylinder
Run the engine

system.
Then
to circulate
(4).
the oil through
the
check the oil level in the hydraulic
tank again.
P2350
I475
30225
METHOD
FOR LIFTING UP ROPS
When lifting the cab, the lock pin which supports the cab must be securely locked. In addition, be extremely careful not to let the cab tilt
at an angle during the lifting operation.
1.
Remove
mounting
bolts (I) of ceiling
of ROPS.
I
2.
Remove floor mat, and loosen

(21, then remove plate (3).
mounting
235CD02108
bolts
3.
Loosen bolt (4), then remove

locks (5).
4.
Loosen bolt (61, and remove cover (7). (Both left

and right)
Cover (7) on the left side of machines
equipped with an air conditioner is fresh air
filter (37), but remove this also.
235COO210<
left and right door
DWG00224
5.
Remove
cab mounting
bolts (8), (9), and (IO).
235CD02111
30-226
0
235COO2112
When
lifting
up the
air conditioner
so
remove
stand
only
cab mount
shown
the
cab,
the
operators
are lifted
15
at the
mounting
seat
same
bolts
and
time,
of
the
in the diagram.
1235FO2293
6.
Disconnect
connecting
wiring
CN79
(11)
between
cab and floor.

*
Push
the
wiring
harness
on
the
right
side
into
the box.
1235FO2294
7.
Tilt steering
post back one stage.
235FO2295
8.
Install
f
chain
When
supplied
block (14) to ROPS and cab.

using
a chain
block,
always
use the
tools
with the machine.
30-227
0
9.
Remove
10. Wind
lock pin (13) installed
up chain
block
and
to cab.
raise
cab
until
ROPS
and
hole of cab lock pin are aligned.
A
*
*
Never
lifting
Before
go
under
the
ROPS
cab
during
the
operation.
lifting
the
wiring
and piping
Check
that
no
cab,
always
check
that
all the
have been disconnected.

parts
hit
or
interfere
with
other
parts.
11. Secure
ROPS and cab with
INSTALLATION
l

When
ports
tion,
lifting
the
During
cab,
must
be extremely
at an angle during
OF ROPS
in the reverse
the
cab
the
lock pin (13).
the
lock
be securely
careful
the lifting
operation,
do
to removal.
pin
which
locked.
not to
let the
sup-
In addicab
tilt
operation.
not
until the cab has been lowered
30-228
0
order
Floor
go
under
the
fully to the floor.
cab
-
surface
for removing cab
DISASSEMBLY
REMOVAL
AND ASSEMBLY
ROPS CAB
OF ROPS CAB
This shows the procedure for lifting up the operators seat and air conditioner
mount at the
same time in the same way as when lifting up
the cab.
When lifting up the cab only, see the section for
Lifting up cab only.
Cab vibration stopper
1) Loosen bolts (4), and disconnect
brackets
(I), (2), and (3) from stopper (5). (Both left
and right)
2.
Remove
bolts (6),
then remove ROPS roof (7).
u
*
Eyebolts
@ (Ml2
x 1.75) : 04530-l
1222
ROPS roof : 160 kg
30-229
0
DISASSEMBLY
3.
AND ASSEMBLY
Remove bolts (81, then remove

left and right)
ROPS CAB
bracket (9). (Both

m
4.
Remove bolts (IO), then remove

(Both left and right)
5.
Remove bolts (12), then remove cover (13). (Both

left and right)
Cover (13) on the left side of machines
equipped with an air conditioner is fresh air
filter (371, but remove this also.
door lock (II).
DWG00225
6.
Remove floor mat, then remove

remove plate (15).
bolts (14), and
7.
Remove
plate (17).
bolts (161, then remove
DWG00224
DECO0037
8.
Disconnect coupler
water piping.
9.
Remove cab mounting

(221, and bolts (23).
30-230
0
(18) of air conditioner
warm
bolts (19), (201, (211, and

a
DISASSEMBLY
AND ASSEMBLY
ROPS CAB
-XT+--s-i-4
-
DEG00039
Remove the bolts with the white paint

the head.
Serial No.: 11001 - 11013: 16 bolts
11014 and up: 18 bolts
(part marked % added)
on
FWD+
DWG00234
10. Disconnect connecting wiring CN79 (24) between

cab and floor.
*
Push the wiring harness on the right side
into the box.
DEG00042
11. Move steering
post 1 stage back.
DEG00043
30-231
DISASSEMBLY
ROPS CAB
AND ASSEMBLY
12. Disconnect connector (25) from

move hose from clamp (26).
hose, then
re-
DWG00235
13. Disconnect couplers (27) and (28) of freon

ing of air conditioner.
14. Lift off cab.

+
Lifting positions:
Cab assembly
4 places marked
pip-
by arrows
: 600 kg
DECO0046
OEG00047
30-232
0
DISASSEMBLY
15. After lifting ROPS column,

then remove ROPS column
ROPS column
& kg
ROPS CAB
AND ASSEMBLY
remove
(29).
bolts
(30),
1151
: 450 kg
DEG00046
INSTALLATION
.
OF ROPS CAB

removal.
in the
reverse
order
to
m
Adjusting cab vibration stopper
1) Front-to-rear direction
Mounting dimensions of stopper
Unit: mm
Ll
Free
After setting
Amount to push in
45
40
5
ROPS/FOPS roof Plate
i)
Set mounting dimension

Ll of stopper
(5) to 45 mm.
ii) Put brackets (1) and (3) in light contact
with stopper (51, then tighten bolts (4)
temporarily.
iii) Tighten adjustment bolt @ six turns, then
tighten bolts (4).
Adjustment
bolt 0: 235-950-5440
bolt 0.
iv) Remove adjustment
2)
Left-to-right direction
Mounting dimensions
3 5
DWG00236
of stopper
Unit: mm
L2
Free
After setting
Amount to push in
47
42
ROFQ'FOPS roof plate
i)
Set mounting dimension

L2 of stopper
(5) to 47 mm.
ii) Put bracket (2) in light contact with stopper (5), then tighten bolts (4) temporarily.
bolt @ three turns,
iii) Tighten adjustment
then tighten bolts (4).
Adjustment
bolt 0: 01010-51075
bolt 0.
iv) Remove adjustment
Outside
+
DWG00237
30-233
0
DISASSEMBLY
AND ASSEMBLY
ROPS CAB
m
Installation
of ROPS roof
m
ROPS roof mounting bolt (6) :
277 f 32 Nm (28.25 f 3.25 kgm}
v,
2)
Rail guide
Adjust rail guide to front or rear so that rail
at rear of cab is at center of rail guide.
Roller
Adjust roller bracket to front or rear so that
clearance between roller and ROPS column
is 4 + 1 mm.
DWG00238
Cab mounting bolt :

110.5 = 12.5 Nm (11.25 2 1.25 kgm}
Unit: mm
Bolt No.
Bolt length
Length of
tube to use
19
30
20
60
Roller
21
465
bra
400
22
365
300
23
25
ROPS column mounting bolt (30) :

1715 + 195 Nm (175 + 20 kgm}
0
Tube
EL
i
o cabin
30-234
0
DWG00240
DISASSEMBLY
ROPS CAB
AND ASSEMBLY
When lifting up cab only

Serial No.: 11001 - 11008
When not lifting up the operators seat and air conditioner mount, the procedure for the following items
is different.
1.
Removal
1) It is unnecessary to remove plates (15) and
(17) and mounting bolts (14) and (16) in Items
6 and 7.
2) It is unnecessary to disconnect coupler (18)
in Item 8.
3) Remove front defroster duct.
a) Remove bolts (33) and (341, then remove
duct (35) and gasket (36).
b) Remove cap (37) and bolt (19) (white),
then remove duct (38).
Duct (38) is tightened together with
*
the cab mounting bolts.
4) Remove cover (32) at rear of operators seat
5)
k?
g
6)
2.
.
mount.
There is a partial change in the bolts to be
m
removed in Item 9.
See diagram on right. (Remove bolts with
red paint also.)
No. of bolts to remove: 18
seat down to
Push backrest of operators
front, then raise cab.
Installation
removal.
in the
reverse
order
DWG00226
DEG00055
21 (White)
to
22IWhite)
116
w
Cab mounting bolt :

110.5 2 12.5 Nm (11.25 = 1.25 kgm}
Unit : mm
Bolt No.
Bolt length
Length of
tube to use
19
30
20
60
21
465
400
22
365
300
31
270
200
(Wh
31 (Red)
22 (White)
Ig(White)
j[(White)
DWG00241
0
b
Tube
1
To
cabin
DWG00303
30-235
0
DISASSEMBLY
AND ASSEMBLY
When lifting up cab only

When not lifting up the operators seat and air conditioner mount, the procedure for the following items
is different.
1.
ROPS CAB
Damper
assembly
Removal
1) It is unnecessary to remove plates (15) and
(17) and mounting bolts (14) and (16) in Items
6 and 7.
2) It is unnecessary to disconnect coupler,(l8)
in Item 8.
3)
4)
5)
6)
Remove bolt (33) from left console box, then

remove cover (34).
Disconnect connector A6 (35).
Remove bolt (36), then remove fresh air filter (37).
Remove bolt (38), then remove damper assembly (40) together with bracket (39).
7)
Remove front defroster duct.

a) Remove cap (41) and bolts (42) and (43),
then remove duct (44) and gasket (45).
b) Remove cap (46) and bolt (19) (white),
then remove duct (47).
Ir
Duct (47) is tightened together with
the cab mounting bolts.
c) Remove bolt (48), then remove duct (49).
8)
Remove cover (32) at rear of operators seat

mount.
(Serial No. 11001 - 11013, only machines
equipped with air conditioner)
DEG00055
30-236
0
DISASSEMBLY
ROPS CAB
AND ASSEMBLY
9)
There is a partial change in the bolts to be

m
removed in Item 9.
See diagram on right. (Remove bolts with
red paint also.)
.
No. of bolts to remove: 18
IO) Push backrest of operators
seat down to
front, then raise cab.
21 (White)
22IWhitel
22fWhite)
jQ(Whlte)
2.
Installation
removal.
in the
reverse
order
20CWhite)
DWG00241
to
a
w
Cab mounting bolt :

110.5 + 12.5 Nm Ill.25
19
Length of
tube to use
Bolt length
Bolt No.
30
f 1.25 kgml
Unit: mm
I
-
20
60
21
465
400
22
365
300
31
270
I
To cabin
DWC00303
200
30-237
0

Serial No.: 11001 12502
k Lower the work equipment to the ground.
k Stop the engine and move the each work
equipment control lever to release the residual pressure in the piping.

k Disconnect the cable from the negative ()
terminal of the battery.
4. Remove right and left articulate cylinder assemblies (4). For details, see Removal and installation of articulate cylinder assembly.
Disconnection
1. Remove the ROPS cab. For details, see Removal and installation of ROPS cab.
2. Lift off floor assembly (1).
023502
5. Disconnect 9 left-hand hoses (5).
3. Remove engine mount brackets (2) and (3).
6. Disconnect grease hose (7) from lower center

pin (6).
30-238
(6)
7. Disconnect grease hose (9) from upper center

pin (8).
023502
8. Disconnect 9 right-hand hoses (10).

9. Disconnect wiring harness (11).
11. Remove bolts (14) and remove lock washers

(15) from the upper and lower center pin
nuts.
Secure plates (16) with bolts (14) temporarily.
(Serial No. 12051 and up)
10. Remove O-rings (12) and (13) from the upper

and lower center pins.
12. Remove upper center pin nut (17).
30-239
(5)
13. Remove upper center pin (8).

Loosen the lower center pin nut.
17. When replacing bushings (21) and (22)

fitted to the rear frame, cut them with
gas.
4
023502
14. Remove nut (18) of lower center pin (6) and

remove lower center pin (6).
3
When removing the nut, take care that the
center pin will not fall.
16. Remove upper and lower plates (16) from

the rear frame.
15. Sling front frame (19) and slowly pull out and
disconnect it from rear frame (20).
Check that all the connections are disconnected.
When disconnecting, take care of the balance of the front frame.
30-240
(5)
18. When replacing bushing (23) fitted to the

front frame, cut it with gas.
5
Connection
Carry out connection in the reverse order to disconnection.
3. Install lock washers (15) to the upper and lower

center pins and tighten the nuts.
a Install plates (16) before tightening the nuts.
(Serial No. 12051 and up)
Install the upper and lower center pins according

to the following procedure.
1. Insert upper and lower center pins (8) and (6) in
front frame (19) and rear frame (20) and then
tighten lower center pin nut (18) so that upper
and lower clearances "A" will be even.
2. After adjusting the clearance, tighten nut (17) of
upper center pin (8) to torque of 255 9.8 Nm
{26 1 kgm} and then loosen it and tighten
again to torque of 215 9.8 Nm {22 1 kgm}.
Install bushings (21) and (22) by expansion fit.
Install bushing (23) by expansion fit.
023502
30-241
(6)
Bleeding air
Bleed air from the hydraulic cylinders. For
details, see Precautions when carrying out
operation, 2. Precautions when carrying out
installation work.
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
023502
30-242
(6)

k Lower the work equipment to the ground.
k Stop the engine and move the each work
5. Disconnect left-hand hoses (5).
equipment control lever to release the residual pressure in the piping.

k Disconnect the cable from the negative ()
terminal of the battery.
Disconnection
1. Remove the ROPS cab. For details, see
Removal and installation of ROPS cab.
2. Lift off floor assembly (1).
023502
6. Disconnect grease hose (7) from lower center

pin (6).
3. Remove engine mount brackets (2) and (3).
7. Disconnect grease hose (9) from upper center

pin (8).
4. Remove right and left articulate cylinder assemblies (4). For details, see Removal and installation of articulate cylinder assembly.
30-243
(6)
8. Disconnect right-hand hoses (10).
11. Remove bolts and washer (14) and remove lock

washers (15) from the upper and lower center
pin nuts.
a When removing, take care not to lose washers (16) between lock washers (15) and
frame.
023502
9. Disconnect wiring harness (11).
10. Remove O-rings (12) and (13) from the upper

and lower center pins.
30-244
(6)
12. Remove upper center pin nut (17).
15. Sling front frame (19) and slowly pull out and
disconnect it from rear frame (20).
a Check that all the connections are disconnected.
k When disconnecting, take care of the balance of the front frame.
13. Remove upper center pin (8).

a Loosen the lower center pin nut.
023502
16. When replacing bushings (21) fitted to the rear

frame, cut them with gas.
14. Remove nut (18) of lower center pin (6) and

remove lower center pin (6).
k When removing the nut, take care that the
center pin will not fall.
17. When replacing bushing (22) fitted to the front
frame, cut it with gas.
30-245
(6)
Connection
Carry out connection in the reverse order to disconnection.
Install the upper and lower center pins according to the following procedure.
1. Insert upper and lower center pins (8) and (6) in
front frame (19) and rear frame (20) and then
tighten lower center pin nut (18) so that upper
and lower clearances "A" will be even.
a Install O-rings (23) to upper and lower center
pins (8) and (6).
2. After adjusting the clearance, tighten nut (17) of
upper center pin (8) to torque of 255 9.8 Nm
{26 1 kgm} and then loosen it and tighten
again to torque of 215 9.8 Nm {22 1 kgm}.
023502
3. Install lock washers (15) to the nuts of the upper

and lower center pins and tighten bolts and
washers (14).
a Be sure to install washers (16) between lock
washers (15) and frame.
30-246
(6)
Install bushings (21) by expansion fit.
023502
Install bushing (22) by expansion fit.
Bleeding air
Bleed air from the hydraulic cylinders. For
details, see Precautions when carrying out
operation, 2. Precautions when carrying out
installation work.
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
30-247
(6)
40
MAINTENANCE
STANDARD
and transfer..
.... .40- 2
Transmission
pump ........................................
40- 4
Transmission
control valve ............................
40- 6
Transmission
solenoid
valve .........................
40-10
Final drive ........................................................
40-I 1
Differential
lock-up pump ...............................
40-12
Tandem drive ..................................................
40-13
Front axle .........................................................
40-14
Steering
cylinder
.............................................
40-16
Disc brake ........................................................
40-17
Parking brake ...................................................
40-18
Spring cylinder
................................................
40-19
Hydraulic
control valve.. .................................
40-20
Hydraulic
cylinder
...........................................
40-22
Hydraulic
pump.. .............................................
40-24
Drawbar and lifter ...........................................
40-26
Blade.. ...............................................................
40-28
Circle rotation
gear .......................................
40-29-I
Ripper ...............................................................
40-30
Frame ...............................................................
40-31
40- 1
0
023502
40-3-2
(6)
MAINTENANCE STANDARD
TRANSMISSION PUMP
023502
SAR (3)-080
Unit: mm
No.
Check item
Clearance between gear

case and side plate gear
Clearance between plain

bearing I.D. and gear shaft O.D.
Pin insertion depth
Spline shaft rotating

torque
Deliver
Engine oil CLASS-CD
45 55C
Criteria
Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
0.06 0.149
0.20
Replace
0
14 0.5
6.9 11.8 Nm (0.7 1.2 kgm)

Pump
speed
(rpm)
Delivery
pressure
(MPa {kg/cm2})
Standard
delivery
(/min)
Repair limit
of delivery
(/min)
2,500
20.6
{210}
184
169
40-5
(6)
2
LOWER VALVE
Serial No.: 11001 - 12012.12016-12018
40-8
0
Unit: mm
Remedy
Criteria
Checkitem
No.
Tolerance
Clearance
between
F-R
spooland
body
I
22
Clearance
betweenlstspooland
Clearance
between
2ndspooland
Clearance
between
3rd
Clearancebetween4th
Clearance
between
Lspooland
Clearance
between
body
22
body
22
spooland
body
22
spooland
body
22
I
+0.013
-0.035
-0.045
-0.035
+0.013
-0.045
-0.035
+0.013
-0.045
I
0.035 0.058
0.035 0.058
0.035 0.058
0.08
0.08
0.08
Replace
body
22
spool and body
22
-0.035
-0.035
+0.013
-0.045
-0.035
+0.013
-0.045
-0.035
+0.013
-0.045
Standard
Ist,2nd,3rd,4th
+0.013
-0.045
0.035 0.058
0.035 0.058
0.035 0.058
0.035 0.058
0.08
0.08
0.08
0.08
size
speed
40-9
Serial No.: 12013 - 12015,
12019 and up
/
/
5
9
2
IO
I
IO
11
13
12
8
SWG00398
40-9-l
0
Unit:
Criteria
Check item
No.
Stasn$rd
Clearance between
Clearance between
,ha~er~Hole
Remedy
1 ;,,:b;
Cle,;ar&xe
F-R spool and body
I
2
mm
1st spool and body
22
-0.035
-0.045
-0.045
-0.035
22
+0.013
0
0.035
0.058
-
0.08
0
+0.013
0.058
0.035
0.08
0.08
0.08
Clearance between
2nd spool and body
22
-0.035
-0.045
f0.013
0
0.035
0.058
Clearance between
3rd spool and body
22
-0.035
-0.045
+0.013
0
0.035
0.058
between 4th spool and body
22
-0.045
-0.035
0
+0.013
0.058
0.035
0.08
0
f0.013
0.058
0.035
0.08
0.08
0.08
Replace
5
6
-
Clearance
between
Clearance between
Clearance
L spool and body
-0.045
-0.035
22
H spool and body
Clearance between pilot reducing

valve spool and body
22
-0.045
-0.035
0
+0.013
0.058
0.035
25
-0.035
-0.045
+0.013
0
0.035 0.058
Standard
10
Free
length
Spring for L., H.,

1st. 2nd. 3rd. 4th speed
Spring for F-R spool
Installation
length
Pilot reducing
valve spring (outer)
12
Pilot reducing
valve spring (inner)
13
Thickness
of pilot reducing
valve
I
I
Installation
load
Free
length
Installation
load
75.7
98.1 N
(1 o kg)
78
47
103 N
(10.5 kg)
60.6
39
104 N
(10.6 kg)
62
43.7
163.6 N
(I 6.7 kg)
11
Repair limit
size
26
19
5.7 N
(0.58 kg)
Replace
99 N
(10.1 kg)
60.1
25.2
155.9 N
(15.9 kg)
5.4 N
(0.55 kg)
3 mm [Pressure per each shim: 0.03 MPa (0.26 kg/cm?)]
Adjust
40-9-2
0
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
Serial No.: 11001 - 12012,
SOLENOID
SOLENOID
VALVE
VALVE
12016 - 12018
i-l
l-h
rl
l-l
l-l/
I
4th
1st
LOW
Hioh
3rd
F
R
40-10
0
MAINTENANCE
STANDARD
Serial No.: 12013 - 12015,
TRANSMISSION
SOLENOID
VALVE
12019 and up
4th
1st
LOW
A-A
SwG00400
40-10-l
0
FINAL DRIVE
235CDO2033
Unit:
No.
Criteria
Check item
Remedy
Preload of bevel pinion bearing
Starting torque:
9.8 - 12.7 Nm (I .O - 1.3 kgm)
Preload of shaft bearing
Starting torque:
9.8 -
Preload of bevel gear bearing
Backlash between
Starting torque:
mm
12.7 Nm (1.0 - 1.3 kgm)
(Starting torque of bevel pinion bearing) + 0.69 - 0.98 Nm

(0.07 - 0.10 kam)(Measured of pinion shaft)
Tolerance
Repair limit
Adjust
ring gear and gear

0.20 - 0.63
1.6
0.25 - 0.33
1.3
Backlash between
bevel gear
bevel pinion and
Backlash between
gear and gear
0.25 - 0.33
1.3
Backlash between
gear and gear
0.17 - 0.44
1.4
40-l 1
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL LOCK-UP PUMP
LOCK-UP PUMP
LAL12
No
-
Check
item
Standard
Clearance
between
gear
case and side plate, gear
Spline
torque
Delivery
(Engine
shaft
Clearance
Remedy
limit
0.15
0.06 - 0.119
0.20
rotating
oil CLASS-CD
45 - 55C)
40-12
0
depth
clearance
0.05 - 0.10
Clearance between plain

bearing I.D. and qear shaft O.D.
Pin insertion
Criteria
Unit:
2.0 - 4.9 Nm (0.2 - 0.5 kgm}

Pump
speed
Delivery
pressure
(rpm)
(MPa {kg/cm%
3500
17.2
I1751
Standard
delivery
Repair limit
of delivery
(Urnin)
(Urnin)
26
23
mm
023502
TANDEM DRIVE
40-13
(6)
023502
40-15-1
(6)
023502
40-15-2
(6)
STEERING
CYLINDER
F23501044
No.
Check item
Criteria
Remedy
Clearance between piston rod and

bushing
40
Clearance between piston rod

support shaft and bushing
60
3
-
Clearance between cylinder bottom

support shaft and bushing
40-16
35
-0.060
-0.142
+0.132
+0.006
0.036 0.274
- 0.060
- 0.090
+0.010
-0.010
0.050 0.100
+0.039
0
0.025 a 103
0.025
- 0.064
Replace
bushing
0.6
0.6
0.6
-1
DISC BRAKE
F23501062
Unit:
No.
Check item
Criteria
Standard size
Thickness
Remedy
Repair limit
of disc
Thickness
Total thickness
of plate
of discs and plates
3.8 i
0.1
2.3 i
0.1
51.1
3.3 2 0.1
1.7
47.1 i
Standard size
mm
Return spring
Free
length
Installation
length
71
52
I
1.7
Replace
Repair limit
Installation
load
247.1 N
(25.2 kg)
Free
length
67
Installation
load
-
40-17
PARKING
BRAKE
Section A -A
F23501063A
No.
Criteria
Check item
Remedy
Standard size
Repair limit
16
Wear of brake pad
Tightening
40-18
torque of mounting
Replace pad
bolt
441.3 - 539.4 Nm (45 - 55 kgm)
Retighten
MAINTENANCE
SPRING
STANDARD
CYLINDER
SPRING CYLINDER
277*31_9Nm
{28.25*3.25bml
SWG00413
Unit:
Standard
1
Piston
5001.4
Play of rod in axial

direction
2.1
Installed
132
dimension
size
Installation
Free length
spring
260
2
Remedy
Criteria
Check item
No.
mm
load
Replace
N {510 kg}
Adjust
of rod
40-19
0
MAINTENANCE
STANDARD
HYDRAULIC
HYDRAULIC
CONTROL VALVE
Serial No.: 11001 - 12022

L.H. VALVE
(Left blade lift, Ripper,
Blade side shift, Power
1.5Nm
0.15!+3
A-A
\
40-20
0
CONTROL
VALVE
MAINTENANCE
STANDARD
R.H. VALVE
Articulate,
Drawbar
side shift and Service)
SWG00403
40-21
MAINTENANCE
HYDRAULIC
STANDARD
CONTROL
VALVE

L.H. VALVE
(Left blade lift, Ripper,
Blade side shift, Power
F-F
\
00.3*9.8Nm
'S*llaml
A-A.
c-c.
B-0
D-D
68.3*9.8Nm
S*lkPml
E-E
SWG00404
40-21-l
0
MAINTENANCE
STANDARD
R.H. VALVE
Articulate,
Drawbar side shift and Service)
88.3i9.8Nm
(9*lkpml
SWG00405
40-2 1-2
0
HYDRAULIC
CYLINDER
Serial No.: 11001 - 12050
F23501109
No
Unit: mm
Check
l-
item
Criteria
Remedy
Clearance
limit
0.6
Blade lift
3learance between
liston rod and bushing
Blade side
shift
65
-0.100
-0.174
+0.262
+0.067
0.167
0.436
0.6
Drawbar
shift
60
-0.100
+0.174
+0.163
+ 0.006
0.106
0.337
0.6
-0.080
-0.142
+0.152
+ 0.007
0.067
0.294
-0.100
-0.174
+ 0.262
+0.067
0.167
0.436
45
Leaning
Articulate
65
0.6
c
0.6
L
Power
0.6
tilt
0.6
Ripper
40-22
0
Replace
Unit:
Check item
Criteria
Blade lift
Blade
shift
Clearance
between
piston rod
support
shaft
(ball joint)
and bushing
(rod end)
side
55
100
Learning
55
Standard
clearance
, ,ole
100
Drawbar
shift
Remedy
Tolerance
Standard
size
-0.05
-0.15
+O.l
0
-0.030
-0.076
+0.174
+O.lOO
-0.05
-0.15
+O.l
0
-0.030
-0.076
+0.174
+O.lOO
mm
0.05
0.25
Clearance
limit
1.0
0.130 0.250
1.0
0.05 0.25
1.0
0.130
0.250
1.0
Replace
Clearance
between
cylinder
bottom yoke
(Support,
support
shaft, support ball
joint) and
bushing
(rod
end)
lift
Blade
shift
side
75
-0.100
-0.174
+0.074
0
0.100
0.248
55
-0.030
-0.076
+0.174
+O.lOO
0.130 0.250
Learning
55
-0.030
-0.076
+0.046
0
0.030
0.122
Articulate
65
-0.030
-0.076
+0.174
+O.lOO
0.130
0.250
Power
85
-0.120
-0.207
+0.087
0
0.120
0.294
-0.120
-0.207
+0.207
+0.120
0.240 0.414
Tightening
torque of
piston nut
Blade
tilt
Rippar
(if equipped)
Blade
lift
Blade
shift
side
go
1.0
1.0
1.0
1.0
1.0
1.0
3.3 5 0.3 kNm
1340 e 34 kgm1 (Width
across
flats:
70 mm)
2.3 2 0.2 kNm
1230 2 23 kgm}
across
flats:
70 mm)
(Width
Drawbar
shift
2.6 + 0.3 kNm
(265 + 26.5 kgm1 (Width
across
flats:
70 mm)
Learning
912 2 91.2 Nm {93.0 + 9.3 kgm1 (Width
across
flats:
50 mm)
Articulate
3.1 2 0.3 kNm
{320 2 32 kgm}
(Width
across
flats:
75 mm)
Power
2.8 2 0.3 kNm
(290 2 29 kgm1 (Width
across
flats:
75 mm)
tilt
Ripper
(if equipped)
4.0 + 0.4 kNm
1405.0 2 40.5 kgm)
(Width
across
flats:
80 mm)
Retighten
I
40-23
0
HYDRAULIC
CYLINDER
F23501109
Check
NC
Clearance between
3iston rod and bushing
item
Remedy
Criteria
Blade lift
65
-0.100
-0.174
+0.262
+0.067
0.167
0.436
0.6
Blade side
shift
65
-0.100
-0.174
+0.262
+0.06?
0.167
0.436
0.6
Drawbar
shift
60
-0.100
+0.174
+0.163
+0.006
0.106
0.337
0.6
Leaning
50
-0.025
-0.087
+0.152
-l-o.007
0.032
0.239
0.6
Articulate
65
-0.100
-0.174
l +0.067
+0.262
0.167
0.436
0.6
65
-0.100
-0.174
+0.262
+0.067
0.167
0.436
0.6
70
-0.100
-0.174
+0.271
+0.075
0.175
0.445
Power
Ripper
40-23- 1
0
Unit: mm
tilt
0.6
Replace
Unit:
Nc3.
-
Check
Clearance
between
piston rod
support
shaft
(ball joint)
and bushing
(rod end)
item
Criteria
1
Blade
lift
Blade
shift
side
110
55
Remedy
Tolerance
Standard
size
Shaft
mm
Standard
clearance
Hole
-0.05
-0.15
+O.l
0
-0.030
-0.076
+0.174
+O.lOO
-0.05
-0.15
+O.l
0
0.05
0.25
Clearance
limit
1.0
0.130 0.250
1.0
0.05 0.25
1.0
Drawbar
shift
110
Learning
55
-0.030
-0.076
+0.174
+O.lOO
0.130
0.250
Articulate
65
-0.030
-0.076
+0.174
+O.lOO
0.130
0.250
1.0
1.0
hl
0
Fi
0
-
~~
Clearance
between
cylinder
bottom yoke
Blade
shift
Replace
side
Drawbar
shift
55
110
-0.030
-0.076
+0.174
+O.lOO
-0.05
-0.15
+O.l
0
-0.120
-0.207
+0.207
+0.120
0.130 0.250
1.0
0.05 0.25
1.0
0.240 0.414
1.0
(Support,
3
support
shaft, support ball
joint) and
bushing
(rod
end)
Ripper
(if equipped)
Blade
Tightening
torque of
piston nut
lift
)l
go
3.3 + 0.3 kNm
(340 + 34 kgm1 (Width
across
flats:
70 mm)
2.3 2 0.2 kNm
(230 2 23 kgm}
across
flats:
70 mm)
2.6 + 0.3 kNm
(265 2 26.5 kgm)
(Width
(Width
across
flats:
70 mm)
1.8 2 0.2 kNm
I180 2 18 kgm}
(Width
across
flats:
60 mm)
Articulate
3.1 k 0.3 kNm
{320 2 32 kgm}
(Width
across
flats:
75 mm)
Power
2.8 2 0.3 kNm
(290 2 29 kgm}
(Width
across
flats:
75 mm)
tilt
Ripper
(if equipped)
4.0 2 0.4 kNm
1405.0 + 40.5 kgm}
(Width
across
flats:
Ret,ghten
.
80 mm)
40-23-2
0
MAINTENANCE
PUMP
PUMP
HYDRAULIC
FOR WORK
VXD70-1 F
HYDRAULIC
STANDARD
EQUIPMENT
98* 9.8Nm
(lO*lbml
amI
I
SWG00406
40-24
0
MAINTENANCE
DRAWBAR
STANDARD
DRAWBAR
AND
LIFTER
AND LIFTER
Serial No.: 11001 - 12050
981+49Nm
~100~5koml
SDG00029
Unit:
No.
Check
item
Wear of ball joint

drawbar
tip
Criteria
at
Clearance
between
and bushing
Clearance between
and
bushing
yoke at blade lift cylinder bottom
40-26
0
yoke
Standard
size
Tolerance
Shaft
Hole
180
-0.05
-0.15
+O.l
0
110
4.035
+0.207
+0.120
75
-0.100
-0.146
+0.074
0
mm
Remedy
Standard
clearance
0.5 - 0.9
0.120
0.242
0.100
0.220
Clearance
limit
0.6
0.5
If it is impossible to adjust
with shims,
reolace ioint
orball joint
Replace
bushing
MAINTENANCE
DRAWBAR AND LIFTER
STANDARD
A-A
0-B
981*49Nm
(100*5bml
G-G
F-F
981*49Nm
~100*5kPml
SOG00030
Unit:
No.
Check
Standard
4
Clearance
between
and drawbar
Clearance
direction
of yoke
in axial
Thickness
of wear
plate
Wear
End play
of wear
of lifter
limit
1.5
1.0 - 2.0
0.3 - 0.8
1.7
Standard
Thickness
Clearance
clearance
circle
Remedy
Criteria
item
plate
bracket
of ball joint
Repair
size
shim
thickness:
0.7 -c 0.2
f it is imposjible to adjust
with shims,
replace circle
guide
Replace
bushing
limit
Standard
mm
Replace
plate
wear
with shims,
replace lifter
bracket
Replace
40-27
0
MAINTENANCE
STANDARD
DRAWBAR
AND
LIFTER
No.
Check item
Criteria
Wear of ball joint at

drawbar tip
Standard
size
180
Clearance between
yoke
and bushing
3
Clearancebetween bushingand
yoke at bladelift
cylinder
bottom
40-27-l
0
110
75
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Cl~;~i;ce
0.5-0.9
-0.05
-0.15
+O.l
0
4.035
+0.207
+0.120
0.120 0.242
0.6
-0.100
-0.146
+0.074
0
0.100 0.220
0.5
with shims,
replace joint
or ball joint
Replace
bushing
MAINTENANCE
STANDARD
DRAWBAR
981*49Nm
~100~5koml
G-G
F-F
AND LIFTER
SWG00408
Unit:
Nt3.
-
Check
Standard
4
Clearance
between
and drawbar
Clearance
clearance
Clearance
direction
of yoke
in axial
Thickness
of wear
plate
1.5
1.0 - 2.0
0.3 - 0.8
1.7
Standard
Repair
size
2
I
Thickness
of wear
plate
Wear
of lifter
End play
Standard
bracket
of ball joint
shim
with shims,
replace circle
guide
Replace
bushing
limit
Replace
plate
wear
limit
circle
5
-
Remedy
Criteria
item
mm
thickness:
0.7 + 0.2
with shims,
replace lifter
bracket
Replace
40-27-2
0
MAINTENANCE
STANDARD
BLADE
BLADE
Serial No.: 11001 - 12050
SDG00031
Unit: mm
No.
Check
Criteria
item
Wear of cutting edge

Wear of side edge
Remedy
Less than 10 mm from blade holder

Repair limit:
Side face 25
Within 10 mm from blade holder
Repair limit:
Wear of blade rail

Standard
Height
Thickness
size
85
35
Repair limit
I
Wear of blade rail guide
40-28
0
Replace
Replace as
soon as one
value
reaches limit
MAINTENANCE
Serial
BLADE
STANDARD
No. 12051 and up

Xl
------;~5------.
V
X
!it
SWG00409
Unit:
Check
item
Wear
of cutting
Wear
of side edge
Wear
of blade
rail
Wear
of
rail
blade
Remedy
Criteria
edge
Less than
I
Repair
limit:
10 mm from
Repair
guide
11
blade
holder
Side face 25
Within
limit:
mm
IO mm from
Height
Thickness
blade
holder
I
Replace
85
35
!gii :it
40-29
0
CIRCLE ROTATION
GEAR
Serial No.: 11001 - 12050
\
.
\7
L.3
F23501412
Unit:
No.
Check item
Criteria
Remedy
Clearance between worm wheel

shaft and bushing
90
-0.036
-0.071
+0.144
+0.052
0.088 - 0.215
0.4
90
-0.036
-0.071
+0.223
+0.065
0.101 - 0.294
0.4
Replace
2

shaft and bushing
Backlash between worm

and worm wheel
Standard

shaft and wear plate
Wear of pinion gear
Thickness of disc
Thickness of plate
Thickness
of disc
Thickness
of plate
10
Total thickness
11
Preload of worm shaft bearing
0.3 - 0.5
2.0
1.o
Standard
40-29- 1
0
of disc and plate
I
I
I
I
I
Clearance
clearance
2.8 O0.1
2.0 f 0.07
3.6 k 0.1
1.7 f 0.05
97.1
limit
Adjust
Repair limit
size
I
I
I
I
I
mm
2.4
_
2.6
Replace
1.5
95.4
Starting torque: 4.9 - 9.8 Nm (0.5 - 1.0 kgm)

(when worm wheel is not meshed)
Adjust
MAINTENANCE
STANDARD
CIRCLE ROTATION
GEAR
swcoo4
Unit:
No
Check
item
Criteria
Tolerance
Standard
size
Clearance
between
worm
wheel shaft and bushing
90
Clearance between pinion gear

bottom collar and bushing
100
Clearance
and worm
-0.036
-0.090
+0.207
+0.120
0.156 0.297
-0.036
-0.090
+0.207
+0.120
0.156 0.297
Clearance
Clearance
limit
0.4
Replace
0.4
limit
worm
0.3 - 0.5
between
blade
wheel shaft
Wear
Thickness
of disc
Thickness
of plate
2.0
-
0.2
Standard
of pinion
Standard
clearance
Hole
clearance
mm
Remedy
Shaft
Standard
Backlash between
and worm wheel
I I
gear
Repair
size
34
Adjust
limit
28
Replace
Preload
ing
of worm
3.2 +
shaft
I
bear-
0.08
2.0 2 0.05
1.8
Starting
torque:
4.9 - 9.8 Nm {0.5 - 1.0 kgm}
(when worm wheel is not meshed)
I
Adjust
40-29-2
0
RIPPER
Section A-A
Section E-E
sectionc-c
Section F-F
Section D-D
F23501124
Unit: mm
No.
Check item
Criteria
Remedy
Tolerance
1
Clearance between pin and

bushing
Standard
size
Shaft
60
Standard
clearance
- 0.025
-0.055
Hole
+0.174
+0.100
Replace
0.125
- 0.229
Standard size
Repair limit
320
170
Wear of point
40-30
0
Clearance
limit
0.5
Replace
023502
FRAME
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
Outside diameter of center pin
Replace
0.036
118 0.090
Remedy
Tightening torque of nut
116.910
1. Adjust nut at bottom pin end when tightening so that clearance A

and B are uniform.
2. After tightening nut at top pin end to 255 10 Nm {26 1 kgm},
loosen once, then tighten again to 235 30 Nm {22 1 kgm}.
Tighten
40-31
(6)
Komatsu America international Company

440 North Fairwav Drive
I
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
PROPOSAL
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR

2
NAME OF COMPANY:
PHONE NO:
:
S
DEPARTMENT:
E
R
NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:

GD825A 2 Workshop

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GD825A 2 Workshop

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SEBM002308

GD825A-2 mount the S6D140-1 and S6D140E-2 engine.

LIST OF REVISED PAGES

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised

LIST OF REVISED PAGE

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

Preparations for work

When removing a cover which is under

Precautions for sling work and making

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

How to read the shop manual

Composition of shop manual

Revision and distribution

Revised edition mark

Weight of parts of component or parts. Caution necessary when

Places that require special attention for tightening torque during

Explanation of terms for maintenance standard

Standard size and tolerance

The tolerance may be indicated in the text

Usually, the size of a hole and the size of

Standard clearance and standard value

Repair limit and allowable value or allowable dimension

Handling of electric equipment and hydraulic component

Points to remember when handling electric

Main failures occurring in wiring harness

Defective crimping or soldering of connectors

High-pressure water entering connector

Oil or dirt stuck to connector

Removing, installing, and drying connectors and wiring harnesses

When removing from clips

When removing a connector from a

Action to take after removing connectors

Heavy duty wire connector (DT 8-pole, 12pole)

Drying wiring harness

Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

Be careful of the operating environment.

Disassembly and maintenance work in the

Do not let any dirt or dust get in during

Change hydraulic oil when the temperature

Handling of connectors newly used for engines

Mainly, following engines are object for following connectors.

Pull lock type (PACKARD-2)

Disconnect connector (1) according to the following procedure.